© 2014, General Electric Company. Proprietary information. All rights reserved.
Cologne, Germany | 3-5, June 2014
Power-GEN Europe
© 2014, General Electric Company. Proprietary information. All rights reserved.
9HA Gas Turbine Validation Milestones A new standard of testing and validating technology
Marcus Scholz
Cologne, Germany | 3-5, June 2014
* Trademark of General Electric Company.
Agenda
• Gas Turbine industry trends
• 9HA heritage and status update
• Testing and validation
• Summary
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Experience matters …
Fired starts
Global installed
base
Fired hours
4,600 units
173 M hours
2.3 M starts
156
120
g
GE
fleet All
others
Reliability 98.2 97.0 +1.2
Availability 92.0 87.9 +4.1
Start Reliability
98.0 97.0 +1.1
Source: ORAP®, All rights to Underlying Data Reserved: SPS®, Modified by GE. Rolling 12 Month Data Apr''12-Mar'13.
4
GT installed base ~1,000 GW ~ half is GE technology
Source: McCoy Power Reports, estimate based on reported orders
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More experience and higher reliability than all others combined
© 2014 General Electric Company. Proprietary Information. All Rights Reserved.
GE’s gas turbine technology trend Advancing world class efficiency
Typical Efficiency vs. Temperature relationship
• H-class… >1430⁰C needed for >60% efficiency
• GE pioneered >1430C a decade ago with “H” class technology
• Six GE H-class units in operation >200,000 operating hours
• Last decade… steam cooling used
• Today… offering largest H-class GT with air cooling
5
1100 1260 1430 1600
52
54
56
58
60
62
2000 2300 2600 2900
Firing Temperature
H Class F Class E Class
CC
eff
icie
ncy
Advancements in materials & technology govern Firing temperature
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Growing efficiency and block size
30%
35%
40%
45%
50%
55%
60%
65%
0
100
200
300
400
500
600
700
800
70's 80's 90's Today
200 MW
400 MW
500 MW 50%
55%
60% >61 %
“E” “F” “H”
Combined Cycle Efficiency
5% lower LCOE (HA vs. F)…
>$20 MM annual
savings per 700 MW plant
$10/MMBtu gas, 6000 h/y
operation
“HA”
600-700 MW
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GE’s product portfolio - 2014 Reliable, flexible, efficient
7
Geared for 50Hz or 60Hz
60Hz Gas Turbines
50Hz Gas Turbines
43 MW
79 MW
90 MW
187 MW 227 MW
130 MW
265 MW 299 MW
470 MW
275 MW
397 MW GE GT-9HA
GE GT-9F
GE GT-9E
GE GT-7HA
GE GT-7F
GE GT-6F
GE GT-6B
GE GT-7E
330 MW
.03
.01
.03
.03
.04
.05
.01
.02
.03
.03
.05
.01
.02
World’s Largest 61%+ Net CC
efficiency
7
50 MW
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A decade of technology advances and lessons learned
DLN 2.6+
HA-Gas turbine platform evolution Three generations of gas turbine technology
9H 2003
9HA 2014
7F.05 2012
9F.05 2005
4-stage VGV 4-stage Turbine
14-stage Compressor Field-replaceable blades 3-stage VGV Advanced HGP
Note: Year denotes first operation
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Advanced Compressor Validated in 2011
• Two fully assembled rotors • Fully instrumented • Full load in 2014
• Tested in June 2011 • Fully mapped compressor • 90 – 110% Speed range
7F-5 compressor 2011 9HA compressor 2013
Validated Capability with growth
© 2014 General Electric Company. Proprietary Information. All Rights Reserved.
State of the art Combustion system
DLN 2.6+ lab tested …
• 210 combustion tests per year
• 150 flow tests per year –
Component/subsystem/piping
• Fuel Flexibility Capability
.. and field validated
• 67 Operating 9 F-class gas
turbine units • >1,300,000 Fired hours
Validated operating & Fuel flexibility
© 2014 General Electric Company. Proprietary Information. All Rights Reserved.
9HA Power turbine experience
Performance and improvements
• Double wall casing for improved clearances
• Advanced Gas Path (AGP) experience from 7F.04 and 7F.05 gas turbines 51 in operation
• 4-stage technology scaled from 9H
Hot gas path materials
• Single crystal technology
• Reduced oxidation and creep • Improved low-cycle fatigue • Air-cooled hardware for flexibility benefits • “F” & “H” - turbine heritage
Many common features with aero and existing ‘H’–class
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Second generation ‘air-cooled’ H-class Gas Turbine supporting 61%+ combined cycle efficiency
9HA Final assembly - January 2014
Turbine features: • Super-alloy rotor materials • F-class materials • Advanced cooling and sealing
Compressor features: • 14-stage, 3D aero design • Pressure ratio 21:1 • 3 stages VSV
© 2014 General Electric Company. Proprietary Information. All Rights Reserved.
9HA Gas turbine transit to test stand
Leaving Belfort - On the Road …
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March 2014: On the barge On the train
9HA Gas turbine transit to test stand
Successfully met shipping constraints for Barge & Train
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9HA preparing for full load test facility Results more relevant than 8,000 hour field tests
Validating the assembled system beyond field conditions
15
Benefits
• Disconnected from grid …
beyond real world testing
• Variable speed, variable load
• Adjustable pressure control
• Comprehensive validation before first fire in the field, with “inducing age”
• Thorough product mapping … confidence in new products
© 2014 General Electric Company. Proprietary Information. All Rights Reserved.
© 2014 General Electric Company. Proprietary Information. All Rights Reserved.
Power train 50m
Starter
motor
Drive motor
Torque converter
Gear box
H-class Gas Turbine
Test cell configuration Full speed full load power train
First engine, 2012: 7F.05 2014: 9HA 2015: 7HA 2016: 7HA.02 Facility can test 50Hz and 60Hz
Advanced compressor
Unique test facility to explore full load and beyond
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Validation details Tests build upon each other… starting with 7F.05 • Exceeding site operating envelope
• Ambient temperature from -37⁰C to 85⁰C
• Compressor flow and pressure capability (surge lines)
• Validated extreme transient behavior
• 90% - 110% speed and up to 115% load
• True Frequency deviations / grid events
• Fast and peaking starts
• Test bed has been verified & design tools
and processes validated in 2012
17
Pressure ratio
Co
rre
cte
d f
low
Capability vs. Fleet results
Gas turbine exceeded expectations
© 2014 General Electric Company. Proprietary Information. All Rights Reserved.
Unfired, Part Speed Testing
Aero Mechanics
Perf/Aero Mapping
Combustion Mapping
Liquid Fuel Testing
Fast Start/Load
Surge Testing
Grid Code Testing
Exh frame cold flow
Rotating stall Part-speed aero Start-up aeromech
No load aeromech Loaded aeromech
Baseload performance Partload performance Comp mapping
Fast start testing Fast loading/ unloading
Combustion modes Hot fuel, cold fuel Load reject to FSNL/islanding
Output lapse mapping Frequency containment
9HA Test schedule - 2014
Water-to-fuel mapping Fuel transfers
Max PR vs IGV/nc Growth space expl.
Over half a year’s testing to replicate an engine life cycle
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9HA 2nd unit site construction EdF Bouchain: Site works ongoing
Control room Piping Rack HRSG + Water treatment
GT Pedestal - 8th stage to exhaust diffuser) On schedule for
Commissioning end of 2015
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Advanced gas turbines 50 and 60 Hz
2011 2012 2013 2014 2015
Analysis and
Modeling
F & H platform alignment
Intro rating
Compressor Test
7F-5 GT Test
9HA GT assy.
9HA GT Test
7HA launch
7HA GT Test
Verifying 9HA
final design
Verifying 7HA final design
9F-7 (9HA)
launch
7HA
9HA
Modular design and technology alignment: • Lessons learned
• Identifying growth potential
• Leveraging 9F and H design
• Commercial Commitments for FlexEfficiency
technology:
− 65x 7F-5 committed (1st COD 2014)
− 6x 7HA committed
− 4x 9HA committed (+1 test, +1 rotor)
>61% efficient technology platform
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21
Summary
Largest output with >61% Combined cycle efficiency for the lowest cost of electricity
Merging of H technology pioneered by GE + 1200 ‘F’-fleet experience
Air cooled with proven materials
Industry leading validation capability for reliable operation over the lifecycle of the turbine
Continuous pipeline of technology development for sustained industry leadership
HA technology validation – setting industry standard