B09 Boon GDF

A view on developments
in Gas Turbines
An overview of suppliers
activities
Gustaaf Boon,
Technology Intelligence Officer
Direction Research & Innovation
Prof. Thermal Power plants VUB
September 24,2010
Essen
GDF SUEZ Some figures
• €79.9 billion in 2009 revenues.
• 1st company in the “utilities” sector worldwide (Forbes Global 2000).
• €30 billion net invested over 2008-2010.
• 72.7 GW of installed power-production capacity.*
• 200,650 employees throughout the world

- incl. 134,750 in energy and services
- and 65,900 in environment.
• 1,200 researchers and experts in 9 R&D centers.
* Including 100% of the capacity of GDF SUEZ assets

at December 31, 2009 regardless of the actual holding rate..
2
Breakdown of power generation in 2009
Breakdown by fuel* Breakdown by region*
53% Benelux
Natural gas & Germany
North Rest
America 30.2% of Europe
France
11.6% 17.9%
296 TWh 8.7%
11% 16.5%
Coal
16% Middle East

16% 15% & Pacific
Hydro power
Nuclear 2% 1% South
1% America
Other Biomass
Wind
and biogas
power
* Including 100% of the capacity of GDF SUEZ

assets regardless of the actual holding rate.
3
What is new for gas turbines? …. and CCGT’s .
• Gas turbines play today an important role in power generation and
will continue to do in the next decades.
• Question to the suppliers: please , give an overview of the recent
developments?
• This presentation summarizes the answers of Siemens, Alstom,
Ansaldo and Mitsubishi.
• Evolutions more then revolutions by optimization of:
 Mass flow , air use for cooling and leaks.

 Temperature, material choose and cooling.
 Improved flexibility
 Improved control systems
 Improved maintenance
4
SGT5-4000F – the workhorse
Overview and Performance
Combustion Chamber SGT5-4000F
Speed rpm 3000

Compressor Turbine Introduction year 1996
Copyright by Siemens Energy 2009

Exhaust Flow SGT5-4000F
kg/s 692
Pressure Ratio 18.2
Exhaust Temperature °C
3000577
Copyright © Siemens AG 2010. All rights reserved.
Speed rpm
Introduction year 1996
GT Power (gross) MW 292
GT Efficiency (gross) % 39.8
CC Power (net) kg/s
Exhaust Flow MW 692 423
CC Efficiency (net)
Pressure Ratio % 18.258.4
24 Hybrid Burners
Exhaust Temperature °C 577
Rotor with GT Power (gross) MW 292

Hirth serration and GT Efficiency (gross) % 39.8
single rod tie bolt CC Power (net) MW 423
CC Efficiency (net) % 58.4
Siemens Energy Solutions, E F ES

SGT5-4000F: Siemens unique features
 Easily accessible annular combustion

chamber w/o cover lift for short inspection
downtime
 Single-crystal turbine blades with thermal
barrier coating and film cooling for
component longevity
 Hydraulic turbine blade tip clearance
control for baseload efficiency
improvement
 All blades removable with rotor in place for
easy maintenance and shorter outages
 Hirth serration with single tie bolt for stiff &
light rotor and quick thermal response due
to internal flow passages allows for world
class fast start up and hot restart
capabilities
Page 6 GdF Suez – VGB Tagung Essen Siemens Energy

SGT5-4000F
Overview Experience
Order status
233 units under contract
thereof 159 units in operation

(+40 license engines sold or running)
Operating experience
> 4.630.000 EOH whole fleet

> 98.000 EOH fleet leader
The Reliability of SGT5-4000F is at a level of 99,6%.
Status: 2009
GdF Suez – VGB Tagung Essen Siemens Energy Solutions, E F ES

Major Upgrades of SGT5-4000F
Successful history is continued with the latest upgrade
step
1st Compressor
Upgrade
Latest
Upgrade

2. Upgrade
292 MW / 39.8%
1. Upgrade
Cooling Air Reduction

Market 287 MW / 39.5%
Introduction
2nd Compressor Upgrade
266 MW / 38.6% Combustor Cooling Air Saving
Hydraulic Clearance Optimization
Fuel Gas Preheating
240 MW / 37.0%
1996 2000 2004 2008

Selection of Recent Single Shaft Projects under
construction in Europe as Reference for SGT5-4000F
Pego, Portugal Pont sur Sambre, France Severn Power, UK

Malzenice, Slovakia Mellach, Austria Rijnmond, Netherland
…demonstrating the superior economics of the Siemens concept allowing also

heat extraction in several projects to raise economy and ecology
Key data
SCC5-8000H 1S output 570 MW

GT output 375 MW
GT efficiency 40%

GT heat rate < 9231 kJ/kWh
Fuel Nat. gas, fuel oil
Grid frequency 50 Hz
Weight 444 t
Length 13,2 m
Height 5,0 m

SGT5-8000H
designed for over 60% efficiency in combined cycle
High cycling capability due to Four stage turbine with advanced

advanced blade cooling system materials and thermal barrier
coating
Advanced
Ultra Low NOx (ULN)

combustion system
Evolutionary 3D- > 60% Combined

compressor blading Cycle efficiency
Proven rotor design, Integrated combined

free radial thermal cycle process
expansion and for economy and
central tie rod low emissions
Siemens Energy Solutions, E F ES

SGT5-8000H: Siemens unique features
 Vane 1 and Blade 1 removable through

combustor for short maintenance downtime
 Turbine Vane Carrier has roll-in/out
capability to avoid rotor to ensure short

maintenance time
 Directionally Solidified turbine blades with
thermal barrier coating and film cooling for
component longevity at reasonable cost

 Hydraulic turbine blade tip clearance control
for baseload efficiency improvement
 Hirth serration with single tie bolt for stiff &
light rotor and quick thermal response due
to internal flow passages allows for world
class fast start up and hot restart
capabilities
 4 stages of fast acting variable-pitch guide
vanes (VGV) for improved part load
efficiency and high load transients

Hydraulic Clearance Optimisation (HCO)
 Hydraulic rotor shift by pistons

behind the compressor thrust
bearing pads
 Clearances are designed for hot
restart and are be reduced with HCO
during operation
 Fail safe design (!) and retrofitable
 performance increase due to higher
performance gain in turbine (conical
flowpath) compared to loss in

compressor (more linear flowpath)
Stationary condition,
Cold Transient condition
geometry after hot restart
Stationary
condition
clearance minimized by HCO – view on pistons
HCO rotor movement

SGT5-4000F Upgrade
Hydraulic Clearance Optimization
Test with constant fuel mass flow (fuel gas valve and IGV
locked) => Power increase when HCO is switched on
Alstom Gas Turbines
GT development direction
VGB Congress
Prepared for GDF Suez

Essen, September 22-24 2010
Introduction
GT product development drivers
• Changing fuel sources • Varying power demand

• LNG • Part load operation
• Fuel quality • Overnight and weekend
shutdowns
Fuel Operating
Flexibility Flexibility
Output
Efficiency
RAM
Environmental
Aspects
Operation within emission

permit levels
Performance with flexibility – for today and the future

VGB Congress - Gas Turbine Developments - provided to GDF Suez - 1000922-24 - P 16
© ALSTOM 2010. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will
apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or
disclosure to third parties, without express written authority, is strictly prohibited.
Gas Turbine requirements
Operational flexibility: responding to demand
Energy Mix
Power Plant load variation
Industry
Private consumers
SCPP and CCPP required to support demand variations.

Renewables capacity growth will increase volatility
GT24/GT26
Development Direction
• Fuel Flexibility: LNG
• Fuel Flexibility: variation in gas composition
• Part-load performance
• Emissions
• Operation at low loads / fast ramp-up
• Lifetime extension
• Reliability

GT24/GT26 Development
Fuel flexibility: natural gas composition
50
• High tolerance to gas GT24/GT26
variations without
40
hardware changes: Typical
- Wobbe Index
range
 5%
Wobbe Index (MJ/m3)
30
+/- 10%
16
- C2+ up to 16%
14 C2+ (%) 20
12
10 10
8
• Fast acting fuel
6 0
composition measurement4
Jan'01 Jan'02 Jan'03 Jan'04 Jan'05
with on-line control 0
03 Oct 17 Oct 31 Oct 14 Nov 28 Nov
09 09 09 09 09
Continuous operation with significant gas variations

Part-Load performance
Relative CC Gross Efficiency 100%
KA24/KA26
Sequential Combustion Turbine
95%
Typical Single Combustion Turbine
90%
85%
80%
40 50 60 70 80 90 100
CCPP Load [%]
Evaluate part load efficiency!

Emissions on gas – clean combustion
GT26 NOx Emission

NOx Emission values*
Typical Permit Level 25 ppm
Single Combustor
Engine Characteristic
LLOC Area**
10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
Relative GT Load
* vppm @ 15%O2, dry
** GT operation point depending on ambient conditions
Low NOx emissions from 100% down to 30%

Operational flexibility: Low Load Operation
• To date operators have had only two options during the
low/negative spark spread periods (typically night-time /
weekends):
– To de-load to the
minimum plant load
point where
emission regulations
are still maintained or
– To shut-down
The unique “Low Load Operating Capability” (LLOC) offers

increasing operational flexibility
Operational flexibility: Low Load Operation
EV combustor
SEV combustor off in lean premix mode
• Engine running with EV combustor only in lean premix mode - emissions
close to base load level
• Steam turbine stays in operation, combined cycle parked at around 20%
relative load
• Power reserve - normal CCPP loading instantly available
CCPP full load in less than 25 minutes

GT24 Development
Operational flexibility & lifetime extension
One common hardware - two operation modes
GT24
Power Optimised Lifetime Optimised

operation mode: operation mode:
- Standard inspection intervals - Extended inspection intervals
28’000 EOH 32’000 EOH
- For high demand periods - For stable demand periods
- Approx. - 2 to 3% power
On-line output, minimal impact on
switch efficiency
over
Perfect for changing power market requirements
GT24/GT26 Development Reliability
GT24/GT26 ORAP RAM Values GT24/GT26

(12 Month Rolling Averages) F Class technology
100%
98%
96%
94%
92%
90%
CY09Q1 CY09Q2 CY09Q3 CY09Q4

Source: SPS / ORAP Market Summary 1Q09 – 4Q09
Ansaldo Energia
Gas Turbines
Upgrades and developments
highlights
2010
Gas Turbines
Product Line
Rating
Model
[MW]
AE64.3A 75
(“F” class)
AE94.2 170
AE94.2K 170 References as of December 2009
(“E” class)
Model Units (op.) MW EOH
AE94.3A 294 AE64.3 15 (15) 930 1,080,000
(“F” class)
AE64.3A 21 (5) 1,430 200,000
AE94.2/.2K 81 (76) 13,032 3,250,000
Reliability > 98% AE94.3A 42 (30) 11,597 730,000
Total 159 (126) 26,989 5,260,000

AE94.3A4 Evolution
Continous Upgrading
After the Siemens License expiring date (October 2004) and based on its
own experience and specific needs of its customers, in the last few years
Ansaldo Energia has continuosly upgraded its Gas Turbine with several
packages allowing:
Performance optimization
Enviromental impact reduction
Increasing in operating flexibility
Enhance availability and reliability
Upgrading life cycle of critical items
Maintenance activities improvement
AE94.3A4 Evolution
Upgrading introduced after licence expiration
Major recent upgrading designed by AEN:
– VeloNOx™ burners to improve NOx emission from 50 to 30 mg/Nmc
– Reduction of Minimum Environmental Load
– Hydraulic IGV actuation system for frequency response (primary and

secondary) according to European standard
– Life cycle analysis of all turbine B&V to improve power output, efficiency
and/or to increase maintenance intervals
– Fogging system
– Flexible hoses for gas and oil on board distribution
– Introduction of new purging system for dual fuel machines
– Premix extension in the GT whole load range

AE94.3A4 Evolution
Continous Upgrading
Fleet equipped with VeLoNOx™ burners to reach NOx

emissions < 30 mg/Nm3 :
– Moncalieri (AE94.3A4, new machine)

– Napoli (AE94.3A2, new machine)
– Vado 1 (AE94.3A2, retrofit)
– Priolo 2 (AE94.3A2, retrofit)
– Mantova 1(AE94.3A2, retrofit)
– Mantova 2 (AE94.3A2, retrofit)
AE94.3A4 Evolution
Continous Upgrading
The new High Pressure Purging allows dual fuel Gas Turbines to
work with higher efficiency and stability, due to the fact that burners
are always kept clean and free of any solid particles.
This system was patented by AEN,

the innovative idea is to use a
water-oil emulsion during the
switch over phases to cool and
wash the fuel oil premix burner.
AE94.3A4 Evolution
Continous Upgrading
AE94.3A Premix extension in the GT whole load range:

 Switch over to premix occurs during the GT start up phase: i.e. at full
speed no load the GT is already in premix mode
 Premix mode is maintained during all fuel gas operation (including load
rejection, grid support, fuel change over, etc.)
 This operation mode has been experienced for the first time on annular
GT by AEN on its own AE64.3A in Terni.
ADVANTAGES:
 No dead time due to burner switch over during loading/unloading
 Possibility to operate in island mode at any load
 Very simple fuel system (easy operation and maintenance)
First Step in New Adventure…
2008 AE94.3A4 2009 improved AE94.3A4 2011+ improved AE94.3A4

+ Power  ++ Power & Efficiency  +++ Power & Efficiency
+ Efficiency  ++ Flexibility  +++ Flexibility
 NOx@15ppm  NOx@15ppm
• TT @ 1250°C…Cooling
• Low NOx @15 ppm… Velonox
Replacing HS with Centre Series 2
Unbladed Disks • Flexibility…Minimal load @ 45%
Cooling Upgrades
Build New Product Platform…
2008 AE94.3A4 2009 improved AE94.3A4 2011+ improved AE94.3A4

+ Power  ++ Power & Efficiency  +++ Power & Efficiency
+ Efficiency  ++ Flexibility  +++ Flexibility
 NOx@15ppm  NOx@15ppm
• TT @ 1250°C…Cooling & HGP

• +8% Mass Flow Redesign
• Replacing HS with Centre • Low NOx @15 ppm… Velonox
Unbladed Disks Series 2
• Flexibility…Minimal load @ 45%
Cooling Upgrades
Current Developments for High 3
5
CC Efficiency and Latest 50Hz
Gas Turbine Experience
T-Point Combined Cycle Plant

MHI Takasago Machinery Works,
Japan
August 2010
MITSUBISHI HEAVY INDUSTRIES, LTD

36
Outline
 Design Approach (air or steam cooling)

Air Cooled G Gas Turbine M501GAC
 Need for higher CC efficiency

Japanese National Project (Target 1,700 ºC T1T)
 Mitsubishi’s latest development

J Series Gas Turbine (1,600 ºC Steam Cooled GT)
 Current 50Hz Large Frame GTs

 M701G2 (measured CC η 59.3% ISO)
 M701F4 (CC η 59.5% ISO)
This document contains information proprietary to Mitsubishi Power Systems, INC. It is submitted in confidence and is to be used solely for the purpose for
which it is furnished and returned upon request. This document and such information is not be reproduced, transmitted, disclosed or used otherwise in
whole or in part without the written authorization of Mitsubishi Power Systems, INC.
M501GAC (Steam to Air)
Turbine
T1c, T1s : Cooling flow adjustment with advanced TBC
T2c : Advanced TBC
T3s : Cooling Flow adjustment
T4s : Aerodynamics
Combustor
Nozzle : Same as Latest G1
Swirler Holder : Same as Latest G1
Transition Piece : Improved Air Cooled
Compressor
Same as G1
38
CO2 Reduction
The need for High Efficiency

50% CO2 Reduction compared with Conventional Steam Turbine Plant
CO2 Emission / kwh
-50%
Conventional M501J GTCC Future GTCC

Steam Turbine
39
Combined Cycle
Performance Comparison
Power Output
C/C Efficiency 700
J Class 670
600
60
G Class
500
Power Output (MW)

498
C/C Efficiency (LHV %)
465 460 460

F Class 400
50Hz 399
55
100º 300 60Hz 312
334 320
C C/C 280 267
200 213
185
167
D Class 144
50
100 114
G/T
TIT(℃)
1200 1300 1400 1500 1600

D Series F Series G Series J Series
Design Features of “J”
“J” Target : C/C efficiency : > 61% (M501J:460MW / M701J:

670MW)
High Pressure Ratio Compressor Experience from H Engine
 Steam Cooled Combustor Experience from G Engine
Combustor  Turbine Technologies from National Project
Proven G Combustor
- Well experienced ULN combustor
- Steam cooled liner
Turbine
Compressor Proven G Turbine
Validated H Compressor + National Project technologies
- 23:1 pressure ratio - Advanced TBC + Cooling
- 3D profile - High efficient aerodynamic technology
- Improved inlet duct - Cooled row4 blade
In operation for 13 years
41
Average Actual Hours: 3,000/year

Average Starts: 170/year
T-Point Combined Cycle Plant

MHI Takasago Machinery Works, Japan
The M501J will be tested at T-Point in 2011
42
Current 50Hz Offerings
 M701G2 (Steam Cooled)

(measured CC η 59.3% ISO)
 M701F4 (Air Cooled)

(CC η 59.5% ISO)
43
M701G2 (50Hz) TEPCO Kawasaki Power Station

Japan M701G2 3 x 1 on 1 (500MW )
2007, 2008, 2009
Additional Orders
Spain M701G2
50 minutes from ignition to more 3 x 1 on 1
than 98% load (hot condition)
Japan M701G2 (2013)
1 on 1
44
M701F4 Main Features
45
Japan / Tohoku Electric Power CO.

Unit NO.4, Sendai Thermal Power Station
Power Output
Gas Turbine 297 MW
Steam Turbine 149 MW
Total 446 MW
Configuration
Single-Shaft Configuration
1 GT + 1 HRSG + 1 ST
Status
Commercial Operation from July
29, 2010
 Plant in Commercial Operation
46
Summary
 A 60Hz air cooled G is undergoing verification at T-Point under actual

operating condition.
 Carbon Constrain Regulations will change the need for “high CC Efficiency “
 A new J Class 1,600 ºC TIT Gas Turbine has been designed for higher C/C
efficiency (lower CO2 emissions). This incorporates:
 compressor technology developed for MHI H class gas turbine
 Technologies developed for Japanese National Project :
a) Advanced TBC
b) High cooling efficiency
c) High loading, High efficiency turbine
 The M701G2 has demonstrated 59.3% CC Efficiency (ISO)
 The first M701F4 reached full load and is being offered for 59.5 % CC
Efficiency.
gdfsuez.com
Thank You
for your attention.
And thanks to the suppliers
for the information.

B09 Boon GDF

Diunggah oleh

Informasi Dokumen

Deskripsi Asli:

Judul Asli

Hak Cipta

Format Tersedia

Bagikan dokumen Ini

Bagikan atau Tanam Dokumen

Opsi Berbagi

Apakah menurut Anda dokumen ini bermanfaat?

Apakah konten ini tidak pantas?

Hak Cipta:

Format Tersedia

B09 Boon GDF

Diunggah oleh

Hak Cipta:

Format Tersedia

A view on developments

• €79.9 billion in 2009 revenues.

• 1st company in the “utilities” sector worldwide (Forbes Global 2000).

• €30 billion net invested over 2008-2010.

• 72.7 GW of installed power-production capacity.*

• 200,650 employees throughout the world

• 1,200 researchers and experts in 9 R&D centers.

* Including 100% of the capacity of GDF SUEZ assets

Breakdown by fuel* Breakdown by region*

16% Middle East

* Including 100% of the capacity of GDF SUEZ

 Mass flow , air use for cooling and leaks.

Combustion Chamber SGT5-4000F

Speed rpm 3000

Copyright by Siemens Energy 2009

Rotor with GT Power (gross) MW 292

Siemens Energy Solutions, E F ES

 Easily accessible annular combustion

Page 6 GdF Suez – VGB Tagung Essen Siemens Energy

Copyright by Siemens Energy 2009

> 4.630.000 EOH whole fleet

The Reliability of SGT5-4000F is at a level of 99,6%.

GdF Suez – VGB Tagung Essen Siemens Energy Solutions, E F ES

Copyright by Siemens Energy 2009

Cooling Air Reduction

1996 2000 2004 2008

GdF Suez – VGB Tagung Essen Siemens Energy Solutions, E F ES

Pego, Portugal Pont sur Sambre, France Severn Power, UK

Malzenice, Slovakia Mellach, Austria Rijnmond, Netherland

…demonstrating the superior economics of the Siemens concept allowing also

SCC5-8000H 1S output 570 MW

Copyright by Siemens Energy 2009

GdF Suez – VGB Tagung Essen Siemens Energy Solutions, E F ES

High cycling capability due to Four stage turbine with advanced

Copyright by Siemens Energy 2009

Evolutionary 3D- > 60% Combined

Proven rotor design, Integrated combined

Siemens Energy Solutions, E F ES

 Vane 1 and Blade 1 removable through

Copyright by Siemens Energy 2009

component longevity at reasonable cost

GdF Suez – VGB Tagung Essen Siemens Energy Solutions, E F ES

 Hydraulic rotor shift by pistons

flowpath) compared to loss in

Page 13 GdF Suez – VGB Tagung Essen Siemens Energy

Prepared for GDF Suez

• Changing fuel sources • Varying power demand

Operation within emission

Performance with flexibility – for today and the future

Power Plant load variation

SCPP and CCPP required to support demand variations.

• Fuel Flexibility: variation in gas composition

• Operation at low loads / fast ramp-up

VGB Congress - Gas Turbine Developments - provided to GDF Suez - 1000922-24 - P 18

Continuous operation with significant gas variations

Relative CC Gross Efficiency 100%

Typical Single Combustion Turbine

Evaluate part load efficiency!

GT26 NOx Emission

Typical Permit Level 25 ppm

Low NOx emissions from 100% down to 30%

The unique “Low Load Operating Capability” (LLOC) offers