New Generation Industrial Gas Turbines for mechanical · PDF fileNew Generation Industrial Gas Turbines for mechanical ... Medium Gas Turbines Small Gas Turbines. AVPG May 2004 24

1

New Generation IndustrialGas Turbines for mechanicaldrive.

Warren Rabey – Sales Manager Oil and Gas

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Introduction

There are 2 distinct types of turbines:AeroderivativesIndustrial

Industrial Gas turbines were designed to address the requirements ofthe Industrial market place and Aero’s were designed for the jet enginemarket.

Market forces for both Industrial and Aero Turbines have gone throughconsiderable change over the last two decades.

These changes have had a negative influence on the success andprofile of the Industrial type of gas turbine:

Fuel ConsumptionMaintenance and ReliabilityNew ApplicationsEnvironmental

We will use two of Siemens newer turbines (Cyclone and GT10C) todemonstrate how the new generation of industrial gas turbines have keptthe beneficial characteristics of industrial design (Maintainability,Reliability, Operability) but inherit higher efficiency, lower emmssions.

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Market Forces - Fuel Consumption

In early years fuel gas was considered 'free'. It was a wasteproduct.

As Gas became more important as a product (and flaring was tobe reduced) its intrinsic value increased.

Today many project structures involve the purchase or selling ofgas, which gives it a actual value.

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Market Forces - Fuel Consumption

A typical 25 MW compression duty will consume about 1.8 - 2Million MMBTU of fuel gas per year.

When fuel gas had a very low value, the total fuel bill was nothigh and the difference in consumption between the gas turbinetypes was not a significant value.

However, using only $2 per MMBTU will give a fuel bill for a unitof about $3.6M per year.

Apply a 25% fuel consumption difference between Aero (33%)and Industrial (26%) and the difference between the two is about$0.9M/year/turbine.

Attitude to fuel cost does have an influence on a Customersbuying decision.

Thus Customers favored Aero turbines.

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Market Forces –Decrease Maintenance Costs

Oil Companies are continually looking for ways to reduce theircosts.

Originally Industrial Turbines were maintained at site andseveral days of lost production

Aero turbines used modularization for ease of maintenance andquick turn around time

However Aero turbines had to be replace more often thanindustrial turbines.

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Market Forces - New Applications

As the fields also became more remote and more marginal.

End Users looked for inventive ways to achieve economicproduction.

Unit size had its partNew integrated package solutions have been in demand

Combined Cycle plantsSteam Turbine

FPSOGas turbine driven axial compressorsGas turbine driven integral geared compressors

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Market Forces - Environment

We are all aware of the issue of the environment and the effecthydro carbon combustion (acid rain, smog, ozone).

Different technology was available. Preference to reduceemissions at source - without using additional auxiliaries /systems.

Dry Low Emission (DLE) system can reduce NOx by a factor of10.

GT10 emissions

0

50

100

150

200

250

300

GT10 conventional GT10B DLE GT10C DLE

ppm

v

NOxCO

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Task

Task

To design and develop the next generation ofIndustrial gas turbine, which will address themarket factors and reposition Industrial gasturbines back as the preferred choice for EndUsers for the next decade.

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Siemens Solution:

The new generation of industrial gas turbines have toaddress the changing Market Conditions:

Fuel consumption Higher peak efficiencies Better Efficiency with newer Blading Low degradation.

Increase Maintainability

New Applications

Environmental Issues

Siemens has address many of these issues with the Cyclone(12.9MW) and the GT10C (30MW)

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Siemens Solution:Fuel Consumption

Nominal Power and Efficiency v.s. Power Turbine Speed

18 000

20 000

22 000

24 000

26 000

28 000

30 000

32 000

34 000

36 000

3 000 3 500 4 000 4 500 5 000 5 500 6 000 6 500 7 000

Power Turbine Rotor Speed, rpm

Nom

inal

Pow

er, k

W

CONDITIONS:Base loadInlet loss = 0 mbarOutlet loss = 0 mbarAmbient pressure = 1.01325 bar (a)Fuel: Gas with LHV = 46 798 kJ/kg

-15 °C

30 °C

15 °C

0 °C

45 °C

30 %

37 %

36 %

34 %

35 %

33 %

32 %

31 %

38 %

50% reduction inspeed but only18% reduction inPower

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Increase the efficiency of the turbine: Blading

Internal cooling ofblades allows forhotter Operationaltemps

Air Flow Air Flow

Thickest Part of the Blade

Double Circular Arc(DCA) Blade Profile

Multi Circular Arc(MCA) Blade Profile

Redesigning the Curvature of the Blades

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Degradation

Nominal deterioration GT10C vs aero derivative- Gaseous fuel

94%95%96%97%98%99%

100%101%102%103%104%105%106%

0 20000 40000 60000

Equivalent Operating Hours

Det

erio

ratio

n

Specific Fuel Consumption

Power Output

Increased Fuel cost

GT10C

Aero derivative

Decreased Power


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Siemens Solution:Fuel Consumption - Example Project

Importance of fuel consumptionDesign Parameter Traditional Industrial Next Generation Industrial GT10C

Design speed (rpm.) 4600…4700 6500

Compressor Selection 17MV5A 12MV5A

Nominal Impeller Diameter (mm) 1100 690

Compressor shaft efficiency (%) 79.6 86.2

Compressor shaft power (kW) 22,177 20,315

Gas turbine shaft efficiency (%) 29.3* 37.3

Overall unit efficiency (%) 23.3 32.2

Fuel consumption (kg/day) 134,405 97,492

Fuel gas cost (USD/year based on 365 days operation and 2 USD/MMBTU)$4,562,150 $3,309,204

Difference of: $1,252,946 per year*source GTW Handbook 2000/01

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Siemens Solution:Package Redesign

Package design

To have a compact design, with short erection and commissioningtimes but still enable an ease of maintenance.

Modularization of the package and the turbine.

Base plate mounted gas turbine and auxiliaries.

Bolted face for compressor skid or alternator skid.

Single lift or three point support potential for package.

Maintenance crane inside enclosure for general activities.

Layout of package to allow access to components for maintenance.

15

Drive End


Simple pipework arrangement

Ease of access to components

In-situ combustor changeout

Accessibility

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Siemens Solution: Reduction of Maintenance

Maintenance Philosophy

To continue with the long times between overhauls and the abilityto carry out activities in-situ or with core engines exchanges.

Develop concepts that addresses the Customers needs formaintaining the turbines in different locations around the world.

The GT10 has 40,000 'equivalent' hours between major overhauls.'Equivalent' hours are a function of load - so with manycompressors applications the part load operation results in moreactual hours between overhauls. In addition to complete engineremoval, there is module removal or the ability to change partsat site.

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TB 5000

TORNADO

TYPHOONSINGLE SHAFT

TYPHOONTWIN SHAFT

CYCLONE

TEMPEST

ZERO STAGE +2 X HP STAGESCOOLED CT 1HIGHER TET

1.25 MECHANICALSCALE

POWER TURBINESCALE

ZERO STAGE ADVANCED

COMPRESSORTURBINE

COMMON AIRCOMPRESSOR

AND COMP. TURBINE

Product Range Growth

Siemens Solution:Reduction of Maintenance

Build on turbine Experience to increase Reliability

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Maintain proven concepts and technology

GT10C

GT10B

InletInlet bellmouth bellmouth adapted to adapted to

higher air flowhigher air flow

Improved designImproved designof CT blade coolingof CT blade cooling

Bolted power turbineBolted power turbineon a bigger radiuson a bigger radius

One additionalOne additionalcompressor stage (no. 4)compressor stage (no. 4) RemovableRemovable

AEV-burnersAEV-burners

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Industrial Turbines have incorporated:

Core Exchanges

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ExcessiveCO & Instability

Emis

sion

s Le

vel

Reactor TempExcessive NOx

NOxCO

Compromise Zone

DLE

CFD COMBUSTOR THERMAL PROFILES

9% 38%27% 26% Combustionair flow

REACTION ZONE TEMP 16750C

REACTION ZONE TEMP 21750C

30% 47% Combustionair flow

23%

Lean Pre-Mix CombustionConventional

Siemens Solution:Environmental Issues

The CO - NOX Compromise

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Entered Commercial Operation 1995

200+ DLE units worldwide

DLE Operation > 2,000,000 Hours

Lead Engine > 50,000 Hours

No extended commissioning required

No reduction in component life

NOx Achieved5-20 ppmV on Gas25-50 ppmV on Liquid

CO - Negligible

Dual fuel DLE operational since April’98


Pfizer Dual Fuel DLE Tempest Full Load Emissions Jul' 01

0

2

4

6

8

10

12

14

15:2

6:01

16:0

4:01

16:4

2:00

17:2

0:00

17:5

7:59

18:3

5:59

19:1

3:59

19:5

1:58

20:3

0:58

21:0

8:58

21:4

6:57

22:2

4:57

23:1

1:56

23:4

9:56

0:27

:56

1:05

:55

1:43

:55

2:21

:55

2:59

:54

3:37

:54

4:15

:54

4:53

:53

5:31

:53

6:09

:53

6:47

:52

7:25

:52

8:03

:52

8:41

:51

Time

Emis

sion

s (v

ppm

)

NOx

CO

10ppmvd NOx "limit"

Normal Shutdown and Restart

Unrivaled Emissions Performance

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Pilot BurnerDouble SkinImpingement

CooledCombustor

Igniter

Main Burner

LiquidCore

Mixing tube ConeGas fuel andLiquid fuel

Liquid fuel injection nozzlePilot and Main

Main gas fuelPilot gas fuel

Flame

Compressor discharge air

Different approaches to DLEcombustion but with the same effect

Medium Gas Turbines

Small Gas Turbines

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Siemens Solution:Gas Turbine Specifications

GT10C Gas Turbine

30MW shaft power.

6500 rpm free power turbine.

37.3% thermal efficiency.

DEL combustion: NOx <15ppmv.

50 - 105% speed range.

Mineral Lube oil system.

Cyclone Gas Turbine

12.9 MW shaft power.

9500 rpm free power turbine.

36.2% thermal efficiency.

DEL combustion: NOx <10ppmv.

50 - 105% speed range.

Mineral Lube oil system.

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Summary

History

Low efficiencyHeavy

Non-DLEGood reliability

Low speed User friendly maintenance

Increased efficiencyLightDLE

Costly maintenanceHigh speed

Complex maintenance

High efficiencyLight industrial

DLEHigh reliability

High speed User friendly maintenance

19801980’’ss Old industrials Old industrials

20002000 New industrials New industrials

19901990’’ssAeroAero’’ss

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Conclusion

Development can not be restricted to a technical perspective. Ithas to match the market requirements.

The new generation of Industrial are developed to address boththe present and future demands of the market place.

Markets are never static but the conservative approach fromEnd Users prevent radical technology change.

We foresee closer integration of the driver /driven machinery,more focused package concepts to address highly specificmarket needs and the development of the maintenance andL.L.C concepts.

Industrial gas turbines will again dominate the market for thedecade to come.

Documents

New Generation Industrial Gas Turbines for mechanical · PDF fileNew Generation Industrial Gas Turbines for mechanical ... Medium Gas Turbines Small Gas Turbines. AVPG May 2004 24