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• BHEL – GE GAS TURBINES COLLABORATION STATUS
• GAS TURBINE FUNDAMENTALS
• DESIGN FEATURES OF BHEL GAS TURBINES
WELCOME TO 1ST SESSION
COLLABORATION WITH GE, USA
Models covered : Fr-1 / Fr-3 / Fr-5 / Fr-6B / Fr-6FA / Fr-9E / Fr-9EC / Fr-9FA / Fr-9H
Period : Started in 1986
Valid upto 2006
Coverage : Gas Turbine & Auxiliaries
Combined Cycle Engineering
Area : Compressive - Engineering
manufacture, E&C & Services
License for manufacture of rotor
and HGP components
HEAVY DUTY GAS TURBINE MODEL DESIGNATION
PG 6 58 1 (B)
APPLICATION SERIES POWER NO. OFSHAFTS
SERIES
M- Mech.. Drive
PG- Pkgd. Gen..
FRAME1, 3, 5, 6, 7, 9
Approx. output powerin Hundreds,Thousands, or 10Thousands ofHorsepower
1 or 2
004
GT MODELS AND RATING
Model ISO Rating (kw) ISO Efficiency (%)
(1) MS1002 5070 24.5(2) MS3142(J) 10450 25.6(3) PG5371(PA) 26300 28.5(4) PG6581(B) 42100 32.0(5) PG6101(FA) 70140 34.2(6) PG9171(E) 123400 33.8(7) PG9231(EC) 169200 34.9(8) PG9351(FA) 255600 36.5(9) PG9551(H) 380,000 -
Note: ISO output is : 15 deg C, 60% RH, Zero MSL, Gas fuel and standard Inlet/Exh. Pr. drops
FUEL(100 %)
GASTURBINE
POWER(29.5 %)
MISC.(3.5 %)
EXHAUST HEAT (67 %)
OPEN CYCLE GAS TURBINE TYPICAL PERFORMANCE
ENTROPY
• EFFICIENCY INCREASES BY 1 POINT FOR EVERY 600 C OF T3•COMBINED CYCLE COMBINES BEST OF :
– BRAYTON CYCLE VIZ: HIGH TEMP HEAT ADDITION (11040 C)– RANKINE CYCLE VIZ: LOW TEMP HEAT REJECTION (45 0C)
EXPECTED COMBINED CYCLE EFFICIENCY = 48% TO 55%
1104 0 C
12000 C
TEMPERATURE
Steam Cycle
Gas Cycle
Q in
A
B C
D
E
1
2
3
4
00 C
450 C
3000 C
6000C
9000 C
Q out
GAS TURBINE REQUIREMENTS
Factors considered in selecting gas turbine
High efficiency High specific output (output/kg of air flow)
Key Parameters of GT Affecting Above
Firing temperature (Limited by metallurgy/cooling technology) Pressure Ratio
MAJOR FACTORS AFFECTINGGAS TURBINE PERFORMANCE
• Ambient Temperature• Altitude above Mean Sea Level (MSL)• Relative Humidity• Inlet Pressure Loss• Exhaust Pressure Loss• Steam / Water Injection for NOX Control• Type of Fuel
PRESSURE DROP EFFECTS (FOR FRAME -5)
4 INCHES H2O INLET DROP PRODUCES :
• 1.75% POWER OUTPUT LOSS• 0.74 % HEAT RATE INCREASE• 1.4 DEG.F EXHAUST TEMP. INCREASE
4 INCHES H2O EXHAUST DROP PRODUCES :
• 0.71 % POWER OUTPUT LOSS• 0.71 % HEAT RATE INCREASE• 1.4 DEG.F EXHAUST TEMP. INCREASE
EFFECT OF STEAM INJECTIONON OUTPUT & HEAT RATE
INLET CHILLING PROCESS
Heavy Duty Industrial Type Skid concept to reduce site-work Horizontally split casing for easy maintenance Axial type compressor with Built-up Rotor Wide Fuel flexibility : Gas & Liquid(light/Heavy)
Mixed Firing also Cannular Combustion system with water/steam injection /DLN combustors to meet stringent emission limits Suitable for Mechanical/Power Generation/Single shaft CCP applications
Constructional Features of BHEL Gas Turbines
Compresor Rotor Each wheel(stage) is bladed & statically balanced Through bolts for wheels assembly Total Rotor is dynamically balanced
Turbine Rotor Each wheel(stage) with buckets & balanced Through bolts for wheels assembly Compressor & Turbine Rotor are built-up type Compressor & Turbine Rotor joined by distance piece to form one Rotor Compressor Stator Vanes & Turbine Nozzles are fixed in Comressor & Turbine Casing
GT Rotor/Stator Arrangement
COMBUSTION SYSTEM Multiple Reverse flow can annular combustor
- easy for maintenance
- longer life due to lower dynamic forces
- allows full scale shop testing for non-standard fuels
- better temperature profile control
- high efficiency & lower emission Each Combustor consisting of fuel nozzle, liner &
transition piece (for connecting to turbine) Retractable electric spark plugs & UV flame detector Cross fire tubes connecting combustors for flame
propagation
GT Cutaway Showing Casing Cross Section
NOx ABATEMENT
Nox is generated by fixation of Nitrogen in combustor
Nox generation depends on
- Flame Temperature
- Retention time in flame zone
- Fuel bound Nitrogen
Nox abatement methods - By steam/water injection in flame zone - By lean pre-mix mode (DLN combustor) - By SCR (Selective Catalytic Reduction)
ACCESSORY BASE
Mainly consists of following systems
- Starting system
- Lube oil/Hydraulic oil system
- Gas/Liquid fuel system
In F-technology GT’s these systems are independent &
off-base modules
STARTING SYSTEM
Electric Motor/Diesel Engine/Gas Expander Torque converter Electrical clutch Hydraulic Ratchet/Rotor turning Accessory Gear Box consisting of - Over speed trip mechanism - Lube oil pump - Hydraulic oil pump - Fuel oil pump - Atomizing air compressor - Water pump Accessory Coupling (Gear, Diaphragm, Membrane))
LUBE OIL & HYDRAULIC OIL SYSTEM
Lube oil tank (as a part of base frame) with heater MOP(shaft driven), AOP(AC) & EOP(DC) Duplex (shell & tube) oil to water heat exchangers Duplex filter (5 micron) with downstream SS piping Main Hydraulic oil pump (shaft driven), AHP(AC) with 0.5 micron filter Cooling water supply - by wet cooling tower - air blast cooler
GAS FUEL SYSTEM
Stop/speed ratio valve, control valve (located in gas module)
On-base SS piping
Gas leakage detector & ventilation for Gas Module
LIQUID FUEL SYSTEM
Shaft driven booster pump (Gear/Screw type) Suction stop & bypass control valve 5 micron high pressure filter Flow divider (for equal fuel distribution) Additionally air atomization by - shaft driven air compressor (air extraction from last stage of compressor, cooled in AAP & boosted) - belt(diesel engine)/motor driven air booster compressor during start-up
Gas Turbine
MS 5001PABasic Product Information
Construction
Compressor stages : 17Turbine stages : 2Number of combustors : 10Pressure ratio : 10.3Firing temperature : 963°CLoad gear box rating : 31500KWLoad gear design : Single helical
MS 5001PA DESIGN FEATURES
17 stage axial compressor Turbine & Accessory bases are skid mounted Accessory base contains starting system, Lube oil console, shaft driven accessory gear box driving Lube, Fuel, hydraulic oil and atomizing air air compressor drives. 1st Nozzles air cooled Diesel/Motor/Expander starting facility Hot end drive. Completely packaged and factory assembled, tested.
MS5001PA
Performance Gas DistillateISO output (KW) 26300 25800ISO heat rate (Btu/KW.HR),LCV 11990 12070ISO efficiency(%) 28.46 28.27Exhaust flow (Kgs/sec) 124.16 124.44Exhaust temp. (°C) 487 488Speed (RPM) 5100 5100105 Combined cycle ISO output (KW) 40 39 Efficiency (%) 42 41.5205 Combined cycle ISO output (KW) 80.5 78.5 Efficiency (%) 42.3 42.0
PLANT ARRANGEMENTS OF MS5001PA
• Machine suitable for Indoor/outdoor installation• Skid mounted GT & Accessory packages• Suitable for Single Shaft and multi shaft combined cycle• Side or top exhaust• On-base / Off-base enclosure
FRAME-5PA GAS FRAME-5PA GAS TURBINETURBINE
PG6581(B) BASIC PRODUCT INFORMATION
CONSTRUCTIONAL FEATURES:
Compressor Stages 17
Turbine Stages 3
Number of Combustors 10
Pressure Ratio 12.2
Firing Temperature (°C) 1140
GT Speed (rpm) 5163
Load Gear Box rating 54 MW
Load Gear Box Design Double Helical
17 stage axial compressor Turbine & Accessory bases are skid mounted Accessory base contains starting system, Lube oil console,
shaft driven accessory gear box driving Lube, Fuel,
hydraulic oil and atomizing air compressor Honey comb seals for 2nd & 3rd stages Air cooled 1st & 2nd stage buckets & Nozzles Diesel/Motor/Expander starting facility Hot end drive Completely packaged and factory assembled, tested
6B DESIGN FEATURES
Performance Gas Distillate
ISO output (kW) 42100 41160
ISO heat rate (kcal/kwhr) 2680 2704
ISO efficiency(%) 32.1 31.8
Exhaust flow (kg/sec) 147 148
Exhaust temp. (°C) 548 549
Speed (rpm) 5163 5163
PG6581 (B) PERFORMANCE
Machine suitable for Indoor/outdoor installation
Skid mounted GT & Accessory packages
Suitable for Single Shaft and multi shaft
Combined cycle
Side or top exhaust
On-base / Off-base enclosure
PLANT ARRANGEMENTS OF 6B
MS 6001B GT CROSS SECTION
TOTAL BHEL GAS TURBINE LOGGED 6.5 MILLION FIRED HOURSTOTAL MACHINES FIRING NAPHTHA 42 AND 1.4 MILLION HOURS FIRING EXPERIENCE
A : 006
TYPE NO OF GAS TURBINESORDER RECEIVED COMMISSIONED
FR-1 4 4FR-3 16 16FR-5 48 44FR-5/2 2 2FR-6B 52 47FR-9E 13 9FR-6FA 7 6TOTAL 142 128
GAS TURBINES FROM BHEL HYDERABAD(as on July 2004)
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