Paper 4 - FlexEfficiency 50 - GE Energy

GE Energy
FlexEfficiency*50
Combined Cycle Power Plant
A new standard of high efficiency and operational flexibility
NTPC O&M Conference

New Delhi February 2012
Shyamal Duggal Krishnakumar PG

Copyright 2012 General Electric Company. Proprietary Information.
* Trademark of the General Electric Company.
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.
2
Overview
FlexEfficiency*50 plant an integrated plant concept Gas Turbine Experience & Customer requirements Major equipment overview Validation and testing full scale test facility Summary
3
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
4
FlexEfficiency*50 plant single shaft

Output (MW) Efficiency (%, LHV)
510 60.3 (GTW launch) > 61% mature

< 40 6 min. from turndown to base load (51MW/min)
Turndown (% B/L)
Ramping rate
CC part load efficiency

Time to 95% load (minutes)
Better lapse rate than current F-technology

28 hot/65 warm/110 cold
(< 8 hours)/(8-72 hours)/(>72 hours)
NOx (mg/m3 @ 15% O2) CO (mg/m3) Min. methane content (%)
50 (30 optional) 30 75
Note: Based on 100% methane, ISO conditions, NOx @15% O2, and other standard plant assumptions 5
Modified Wobbe Index (%) +/-10
Gas turbine experience and Future customer requirements
9F platform product evolution

Continual product improvement
1987 1988
GE introduces F-class platform
First F-class Gas Turbine in operation

9F Gas Turbine tested at load, commercial operation
40 39
9FB.05
1992 1999
2002 2005
9FB.03
38
Efficiency (%)
F-class gas turbines meets 1 million hours of operation 1st 9FB Gas Turbine introduced
9FB.01 9FA.03
37 36
9FB Gas Turbine FSFL testing, DLN 2+ introduced
9FA.02
9FA.01 9F.01
2007 2010 2011
1,000th
F-class gas turbine unit shipped

F-class - 35 million hours and 700,000 starts New 9FB Gas Turbine introduced
35
34 200
220
240
260
280
300
338
Power (MW)
Over 230 9F Gas Turbine with 9 million fired hours and 90,000 fired starts.
7
Future customer requirements

Industry changes
CO2 emission cost
Volatility of grid capacity

UK Generation profile 2008 vs. 2030
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
Source: July 2009 Poyry Energy Consulting 8

FlexEfficiency*50 plant
with integrated solar
First launch project in Turkey,
FlexEfficiency*50 plant 470 MW at site conditions +50 MW concentrated solar +20 MW wind turbines
(>69% total plant peak efficiency)
operation commencing 2015
Integrated Renewable Combined Cycle Scope:
Thermal Solar (CSP):

Modular eSolar tower technology Direct steam generation Fully integrated in steam cycle
TM
9
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
10
Key components
Gas turbine >40% SC efficiency industry leading OpFlex application
Generator Reduced site assembly, full grid code capability
Integrated approach
Steam turbine 40% shaft efficiency SS: 3 casing, lateral exhaust MS: Opposed-flow HP/IP Plant design Smaller footprint, improved serviceability Plant controls Digital architecture, performance seeking algorithms
11
Major equipment overview
9FB gas turbine overview

3D aero turbine, increased T-fire
3D aero, scaled compressor
7FA Gas Turbine (version .05) heritage 3-dimensional aerodynamic design IGV + multi-stage VGV
4-stage hot gas path Advanced aero and sealing Existing materials air cooling
DLN 2.6+ evolution combustion

Proven DLN 2.6+ technology F-class materials Fuel flexibility wide wobbe
13
Advanced compressor technology

Performance
3-D Aero, 14 stages Hybrid radial diffuser Increased airflow
Operability
IGV + multiple VSV stages Non-integral bearing Additional sensors Model based controls Field replaceable blades Improved borescope Blade health monitoring Automated water wash
Maintainability
Next generation of 3-D aerodynamic airfoil

14
Proven DLN 2.6+ combustion system
Emissions
25 ppm NOx, 9 ppm CO 25ppm CO max turndown
Design
Dual-fuel capable Model based control
Experience
> 354,000 hours > 5,000 starts
15
Power turbine technology

Performance and improvements
Hot gas path evolution 3D aerodynamic design Improved clearances 3 and 4 stages experience Lessons learned Single crystal technology Reduced oxidation Reduced creep Improved low cycle fatigue
Advanced aero features

Advanced shapes Buckets and diffuser
Hot gas path materials
GE aircraft rig testing

3D Aero
Validated CFD
Unsteady flow CFD tools
CFD Data
Gas Temperature
Building on field, rig and shared GE Aviation experience

16
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
17
109 SS generator overview

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
Over 600 liquid-cooled generators in operation

18
Model based control

Where am I?
T flame f/a CO NOx
GPS technology for your plant

PR
Ma T fire
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
Tx
When will I arrive?

Enables prediction of equipment capability for more intelligent bid and dispatch decisions
CPR
Digital control architecture for operability and reliability

Fieldbus technologies 50% less wire Easy installation and commissioning one TA Skid validation and commissioning at supplier
MW 200 150 100 50 0 06:50 07:00 GT1 ST GT2 07:20 07:30 03/12/09 07:21
Time
Advanced controls delivering performance, operability and availability

19
World-class test facility
Thorough validation plan

Compressor rig drive train Greenville
Torque converter Compressor rig Gear box Gas turbine driver
Drive motor
Combustion rig dynamics, emissions
Starter motor
Exhaust rig performance
Variable Stator Vane rig durability
Diffuser rig performance
Inlet rig blade durability
Full-speed full-load engine test - Greenville Component , system and unit validation
21
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
22
Question & Answers

Paper 4 - FlexEfficiency 50 - GE Energy

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Paper 4 - FlexEfficiency 50 - GE Energy

Uploaded by

Copyright:

Available Formats

GE Energy

A new standard of high efficiency and operational flexibility

NTPC O&M Conference

Shyamal Duggal Krishnakumar PG

FlexEfficiency*50 Combined Cycle Power Plant

FlexEfficiency*50 plant single shaft

510 60.3 (GTW launch) > 61% mature

CC part load efficiency

Better lapse rate than current F-technology

NOx (mg/m3 @ 15% O2) CO (mg/m3) Min. methane content (%)

Modified Wobbe Index (%) +/-10

Gas turbine experience and Future customer requirements

Copyright 2012 General Electric Company. Proprietary Information.

9F platform product evolution

First F-class Gas Turbine in operation

9FB Gas Turbine FSFL testing, DLN 2+ introduced

2007 2010 2011

F-class gas turbine unit shipped

Future customer requirements

Volatility of grid capacity

Start-up fuel cost

Part load operation more frequent/ efficiency increase

Source: July 2009 Poyry Energy Consulting 8

operation commencing 2015

Integrated Renewable Combined Cycle Scope:

Thermal Solar (CSP):

Fewer systems = simplification

Major equipment overview

Copyright 2012 General Electric Company. Proprietary Information.

9FB gas turbine overview

DLN 2.6+ evolution combustion

Advanced compressor technology

Next generation of 3-D aerodynamic airfoil

Proven DLN 2.6+ combustion system

Copyright 2012 General Electric Company. Proprietary Information.

Power turbine technology

Advanced aero features

Hot gas path materials

GE aircraft rig testing

Building on field, rig and shared GE Aviation experience

109D-14 steam turbine single shaft

109 SS generator overview

Over 600 liquid-cooled generators in operation

Model based control

GPS technology for your plant

Where can I go?

When will I arrive?

Digital control architecture for operability and reliability

Advanced controls delivering performance, operability and availability

World-class test facility

Copyright 2012 General Electric Company. Proprietary Information.

Thorough validation plan

Combustion rig dynamics, emissions

Variable Stator Vane rig durability

Diffuser rig performance

Inlet rig blade durability

Question & Answers

Copyright 2012 General Electric Company. Proprietary Information.

You might also like