Heavy Duty Gas Turbine

Overview

1
Copyright 2004 – Nuovo Pignone S.p.A. Copyright 2006 – Nuovo Pignone S.p.A.
Training Program

1 - Gas Turbine General Overview Installation layout Main

equipment location

2 - Operating Principles Describe the gas turbine

thermodynamic cycle, main
parameters and performance

3 - GT Componentes Description Describe in detail all gas

turbine componentes and
their functions

2
Training Program

4 - Main GT Auxiliary Systems Describe the Auxiliary

systems, P&ID

5 - Gas Turbine Control System Basic of Control and

Protection System, Start-up
and Shut-down sequences

6 – Maintenance Overview Scheduled and Borescope

Inspection, Disassembling and
reassembling procedures,
Components acceptability
criteria

3
What is a Gas Turbine?

Gas Turbine is an engine as

a four cycle reciprocating
engine

•It’s an high technology engine

•It’ an high speed rotating machine (3.000÷30.000 rpm)
•In industrial application may drive generators (GD = Generator Drive) or pumps and
compressors (MD = Mechanical Drive)
•It’s used for mobile application as aircraft ships etc.
•Power range of gas turbine is between 100 kW and 350 MW
•It’s efficiency is between 25% and 40%
•High specific power (light and powerful machine)
•May use a large typology of fuels (gas and liquid types)
•It may operate continuously without stop as long as for one year

Additionally for power higher than 500 kW it has

•Low cost of installed kw

•Low maintenance costs

4
What is a Gas Turbine?

The primary scope is….

To produce mechanical
energy at low cost and
continuously!!

5
How a Gas Turbine Works
IT DIRECTS HIGH PRESSURE, HIGH
TEMPERATURE AIR TO THE TURBINE
SECTION, WHICH CONVERTS
FUEL THERMAL ENERGY INTO
MECHANICAL ENERGY
THAT MAKES
THE SHAFT REVOLVE;
THIS SERVES,
ON THE ONE HAND, TO
SUPPLY USEFUL ENERGY
TO THE DRIVEN
FUEL MACHINE, COUPLED TO
THE MACHINE BY MEANS OF
A COUPLING AND, ON THE OTHER HAND,
• IT EXHAUST
TO SUPPLY ENERGY LOW
• IT PRESSURE,
NECESSARY FORLOW
INCREASES TEMPERATURE
AIR COMPRESSION,
THE ENERGY LEVEL
GASES RESULTING
WHICH
OF THE FROM THE
TAKES
COMPRESSED ABOVE-MENTIONED
PLACE
AIR IN
• BY AADDING
IT DRAWS TRANSFORMATION
COMPRESSOR
INAND
AIR • IT COMPRESS
DIRECTLY
BURNING
FROM FUEL
THE WITHINTO
INIT THETHE ATMOSPHERE.
TO HIGHER PRESSURE
TURBINE
COMBUSTION
SURROUNDING SECTION
CHAMBER
ENVIRONMENT

6
Nuovo Pignone

GAS TURBINES
GENERAL
OVERVIEW

7
Gas Turbine Families
HEAVY DUTY JET

SINGLE TWO SHAFTS “PURE

SHAFT AEREONAUTICAL”
“PENGIUN TURBINES”

INDUSTRIAL & MARINE USE

LM SERIES

INDUSTRIAL USE INDUSTRIAL USE PGT/GE SERIES

8
Gas Turbines Product Range
Solid Technology Base …
GE 5-1 5.5 MW
GE 5-2 5.6 MW
... For Every Application
GE 10-1 11.2 MW 9 High Efficiency,
GE 10-2 11.7 MW Reliability & Availability
LM 1600/PGT 16 14.2 MW 9 Low Life- Cycle Costs
LM 2000/PGT 20 18.1 MW 9 Application Flexibility
LM 2500/PGT 25 23.2 MW 9 Fuel Flexibility
MS 5001 26.3 MW 9 Low Emissions
MS 5002C 28.3 MW
MS 5002E 30.0 MW
LM 2500+/PGT 25+ 31.3 MW
MS 5002D 32.5 MW
MS 6001B 42.1 MW
LM 6000 44.7 MW
MS 7001EA 85.1 MW
MS 9001E 123.4 MW Multi Shaft
Single Shaft

9
PGT 5/1
KEY DATA
• The PGT5/1 heavy-duty gas turbine has been designed
with modular concepts to facilitate accessibility and
maintainability.
• The gas generator consists of a 15-stage, high efficiency,
axial-flow compressor directly coupled to a two stage
turbine.
• The PGT5 has a single combustion chamber system
which is rugged, reliable and able to burn a wide range of
fuels, from liquid distillates and residuals to all gaseous
fuels, including low BTU gas.
• It is specially designed for small power generation and
cogeneration
PERFORMANCE (@ ISO CONDITIONS; MD)
· Output : 5.220 Kw Weight: 28.000 Kg
· Efficiency : 26,9 %
· Heat Rate : 13.422 kJ/kWh
· Ex. Gas Flow : 24,6 kg/s
· Ex. Gas Temp. : 524 °C
· Nominal Speed : 11.140 rpm

10
PGT 5/2
KEY DATA
• The PGT5/2 heavy-duty gas turbine has been designed with
modular concepts to facilitate accessibility and maintainability.
• The gas generator consists of a 15-stage, high efficiency,
axialflow compressor directly coupled to a single stage turbine.
• The low pressure shaft is a single-stage, high-energy
turbine, with variable second stage nozzles which grant
maximum flexibility for mechanical drive service.
• The PGT5/2 has a single combustion chamber system which
is rugged, reliable and able to burn a wide range of fuels, from
liquid distillates and residuals to all gaseous fuels, including
low BTU gas.
• Typical applications include pump drive for oil pipelines and
compressor drive for gas pipelines. Also used in PG
Weight: 28.000 Kg

PERFORMANCE (@ ISO CONDITIONS; GD & MD)

· Output : 5.450 Kw
· Efficiency : 26,9 %
· Heat Rate : 13.422 kJ/kWh
· Ex. Gas Flow : 24,6 kg/s
· Ex. Gas Temp. : 524 °C
· Nominal Speed : 11.140 rpm
11
GE 5/1
KEY DATA

• Single Shaft ideal Prime Mover

for Industrial Cogeneration
• 50Hz or 60Hz Power Generation
• 11 stage Compressor scaled from GE10
• DLE Combustion System
• High Reliability & Maintainability
• Compact Package
• Low Maintenance Cost.

PERFORMANCE (@ ISO CONDITIONS; MD)

Weight: 23.900 Kg
· Output : 5.500 Kw
· Efficiency : 30,7 %
· Heat Rate : 11.740 kJ/kWh
· Ex. Gas Flow : 19,6 kg/s
· Ex. Gas Temp. : 574 °C
· Nominal Speed : 16.630 rpm

12
GE 5/2 (New Product)
KEY DATA
• Twin Shaft driver for Centrifugal
Compressors and Pumps
• 3D Aero
• Advanced static and brush seals
• New coatings
• Advanced compressor design
• Optimization of clearances

PERFORMANCE (@ ISO CONDITIONS)

Weight: 24.000 Kg
· Output : 5.600 Kw
· Efficiency : 31,5 %
· Heat Rate : 11.428 kJ/kWh
· Ex. Gas Flow : na kg/s
· Ex. Gas Temp. : na °C
· Nominal Speed : na rpm

13
PGT 10 A (two shaft)
KEY DATA
• The PGT10 A/2 design goals are: high performance, high
reliability and availability, easy maintenance concepts.
• High technology design: High pressure ratio, firing
temperature level in line with second generation gas
turbines, variable axial compressor stator vanes and power
turbine nozzles.
• The PGT10 combustion system consists of a single
combustion chamber suitable for a large variety of gaseous
and liquid fuels.
• Typical applications for PGT10 are natural gas
compression, centrifugal pump drive and process
application, Offshore applications.
PERFORMANCE (@ ISO CONDITIONS)
MD GD
Weight: 34.000 Kg
· Output : 10.660 10.220 Kw
· Efficiency : 32,5 31,4 %
· Heat Rate : 11.250 11.540 kJ/kWh
· Ex. Gas Flow : 42,3 42,1 kg/s
· Ex. Gas Temp. : 493 484 °C
· PT Nominal Speed : 10.800 10.800 rpm

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GE 10/1
KEY DATA
• Derivative of PGT10A - 2.000.000+
hours experience
• High efficiency high pressure ratio Compressor with
less stages - 11 Vs 17
• DLN combustion system available
• Good Reliability & Maintainability
• Low maintenance cost

• Model available may Have combustion chamber horizontal or vertical

according customer request

PERFORMANCE (@ ISO CONDITIONS; GD)

· Output : 11.250 Kw Weight: 34.000 Kg

· Efficiency : 31,4 %
· Heat Rate : 11.481 kJ/kWh
· Ex. Gas Flow : 47,5 kg/s
· Ex. Gas Temp. : 482 °C
· Nominal Speed : 11.000 rpm

15
GE 10/2
KEY DATA
• Turbine designed and developed by Nuovo Pignone Since
reliability and availability to worldwide customers while keeping with
easy maintenance concepts.
• Two shafts for mechanical drive and single shaft for power
generation and cogeneration applications.
• The GE10 Gas Turbine, with its ability to burn different fuels
(natural gas, distillate oil, low BTU fuel), can be installed in many
countries with different environmental conditions continental,
tropical, offshore and desert.
• Oxides (NOx) reduction in order to meet present and future
standards for pollutant emissions.
Weight: 40.000 Kg
PERFORMANCE (@ ISO CONDITIONS; MD)
· Output : 11.615 Kw
· Efficiency : 32,5 %
· Heat Rate : 11.121 kJ/kWh
· Ex. Gas Flow : 46,9 kg/s
· Ex. Gas Temp. : 488 °C
· Nominal Speed : 7.900 rpm

16
PGT 16
KEY DATA
• First unit in operation 1991
• Based on proven LM 1600 GG and
NP developed heavy duty power turbine
• High efficiency
• Proven reliability in MD and PG applications
• Effective DLE system

This turbine use some power turbine of PGT 10/A and GE 10/2

PERFORMANCE (@ ISO CONDITIONS)

MD GD
· Output : 14.252 13.735 Kw
· Efficiency : 36,2 34,9 % Weight: 19.000 Kg
· Heat Rate : 9.939 10.314 kJ/kWh
· Ex. Gas Flow : 47,4 47,4 kg/s
· Ex. Gas Temp. : 493 493 °C
· PT Nominal Speed : 7.900 7.900 rpm

17
PGT 25
KEY DATA
• Power Turbine developed by Nuovo
Pignone in the early ‘80s
• First unit installed in 1983
• M.D. & P.G. fleet firing hours exceed
1,800,000

PERFORMANCE (@ ISO CONDITIONS)

MD GD Weight: 38.000 Kg

· Output : 23.261 (shaft) 22.417 (el.) Kw

· Efficiency : 37,7 (shaft) 36,3 (el.) % PGT25 Power Turbine
· Heat Rate : 9.560 (shaft) 9.919 (el.) kJ/kWh
· Ex. Gas Flow : 68,9 68,9 kg/s
· Ex. Gas Temp. : 525 525 C
· PT Nominal Speed : 6.500 6.500 rpm

18
PGT 25+
KEY DATA
• Designed by Nuovo Pignone using G.E.
LM 2500 Plus gas generator
• The PGT 25 + is a last generator,
30 MW size
• First unit in operation during 1997
• Fleet firing hours exceed 100,000

PERFORMANCE (@ ISO CONDITIONS – MD & PG)

· Output : 31.364 Kw
· Efficiency : 41,1 %
· Heat Rate : 8.754 kJ/kWh
¾ Natural Gas Fuel
· Ex. Gas Flow : 84,3 kg/s
¾ Dry Operation
· Ex. Gas Temp. : 500 °C (no steam or water
injection)
· PT Nominal Speed : 6.100 rpm
¾ Base Load
19
MS 5001 KEY DATA
• The MS5001 single shaft turbine is a compact heavy-
duty turbine designed for long life and easy
maintenance.
• The MS5001 gas turbine is the ideal solution for
industrial power generation where low maintenance,
reliability and economy of fuel utilization are required.
• Low investment costs make the MS5001 package
power plant an economically attractive system for peak
load generation.
• The MS5001 is ideally suited for cogeneration
achieving very high fuel utilization indexes
• Typical applications are industrial plants for
cogeneration of power and process steam or in district Weight: 87.430 Kg
heating systems.

PERFORMANCE (@ ISO CONDITIONS; GD)

· Output : 26.300 Kwe
· Efficiency : 26,3 %
· Heat Rate : 12.650 kJ/kWh
· Ex. Gas Flow : 124,1 kg/s
· Ex. Gas Temp. : 487 °C
· Nominal Speed : 5.100 rpm
20
MS 5002C / MS 5002D
KEY DATA

• Low capital & maintenance cost

• Long maintenance intervals
• Fleet leader in excess of
100.000 running hours
• More than 420 units worldwide

PERFORMANCE (@ ISO CONDITIONS) Weight: 110.000 Kg

MS5002C MS5002D

· Output : 28.340 32.580 Kw

· Efficiency : 28,8 29,4 %
· Heat Rate : 12.470 12.239 kJ/kWh
· Ex. Gas Flow : 124,3 141,4 kg/s
· Ex. Gas Temp. : 517 509 °C
· PT Nominal Speed : 4.670 4.670 rpm

21
MS5002E (New Product)
Features
• Leverage GE Technology
• Moderate Firing Temperature
• Reliability & Efficiency as
Key Factors
• DLN System derived from
large Frames
• Twin Shaft - suitable for MD or PG Rotordynamic Test

Introductory Performance
z Output Shaft : 30 MW
z SC Efficiency : 36,4 %
z LPT shaft speed : 6.100 rpm
CTV Test Rig
z Exhaust Temp. : 523 °C
z NOx Emission : 25 ppm CTV Compressor Test

Weight: 117.000 Kg
22
LM 6000
KEY DATA

• Most efficient GT in its class

• Proven high reliability and availability
• Generator & Mechanical drive applications
• 3 + millions cumulating operating hours

PERFORMANCE (@ ISO CONDITIONS – PG; MD)

Weight: 31.000 Kg

· Output : 43.076 kW
· Efficiency : 41,3 %
· Heat Rate : 8.707 kJ/kWh
· Ex. Gas Flow : 131,0 kg/s
· Ex. Gas Temp. : 449 °C
· PT Nominal Speed : 3.600 rpm

23
MS 6001 B
KEY DATA
• The MS6001 is a single shaft heavy-duty gas turbine. Its
design was based on the well proven mechanical features
of the MS5001 in order to achieve a compact, high
efficency unit.
• The MS6001 is widely applied in power generation
applications for base, mid-range and peak load service.
• Other typical applications include driving of process
machines, such as compressors, in LNG plants.
• Combined cycle plants based on MS6001 achieve very
high efficiencies with higher availability and reliability. Weight: 96.000 Kg

PERFORMANCE (@ ISO CONDITIONS)

MD GD
· Output : 43.530 (shaft) 42.100 (el.) Kw
· Efficiency : 33,1 (shaft) 32,06 (el.) %
· Heat Rate : 10.852 (shaft) 11.230 (el.)
kJ/kWh
· Ex. Gas Flow : 145 145,8 kg/s
· Ex. Gas Temp. : 544 552 °C
· Nominal Speed : 5.133 5.100 rpm
24
MS 7001 EA
KEY DATA
• The MS7001EA is a single shaft heavy-duty gas turbine
for power generation and industrial applications requiring
the maximum reliability and availability.
• With design emphasis placed on energy efficiency,
availability, performance and maintainability, the
• MS7001EA is a proven technology machine with more
than 500 units of its class in service.
• Typical applications in addition to the 60Hz power
generation service are large compressor train drives
forLNG plants.
PERFORMANCE (@ ISO CONDITIONS)
MD GD Weight: 121.000 Kg

· Output : 81.590 (shaft) 85.100 (el.) Kw

· Efficiency : 32,67 (shaft) 32,73 (el.) %
· Heat Rate : 11.020 (shaft) 11.000 (el.)
kJ/kWh
· Ex. Gas Flow : 278 300 kg/s
· Ex. Gas Temp. : 546 537 °C
· Nominal Speed : 3.600 3.600 rpm
25
MS 9001 E
KEY DATA
• The MS9001E is a single shaft heavy-duty gas
turbine.
• It was developed for generator drive service in the
50 Hertz market.
• The MS9001E is widely applied in power generation
for base, mid-range and peak load service.
• Combined cycle plants based on MS9001E achieve
very high efficiencies with higher availability and
reliability than conventional thermal plants.
• Newest field of application is LNG for MD Weight: 217.500 Kg

PERFORMANCE (@ ISO CONDITIONS – PG & MD)

· Output : 126.100 kW
· Efficiency : 33,8 %
· Heat Rate : 10.650 kJ/kWh
· Ex. Gas Flow : 418 kg/s
· Ex. Gas Temp. : 543 °C
· PT Nominal Speed : 3.000 rpm

26
MS 9001 FA

27
MS 9001 H

28
 Output Range

Nuovo Pignone 32,5 Mw

29 Mw
OUTPUT POWER 26 Mw

23,2 Mw

14 Mw
10,5 Mw 12 Mw

6 Mw For any further need,

5 Mw please find NP on Internet
at the following andress:

2 Mw

http://www.gepower.com/nuovopignone
29
 Load Applic.

Gas Turbines Service according load type

SINGLE SHAFT GAS TURBINES DOUBLE SHAFT GAS TURBINES

30
 HD GT Families

Heavy Duty Gas Turbine Families

HEAVY DUTY

SINGLE TWO SHAFTS

SHAFT

INDUSTRIAL USE

31
 GT Applic. Field

Gas Turbines Applications

Liquified Natural
Gas Plants
Gas Booster, Pipeline Petrochemical
and Re-injection Plants

Gas Turbines produced

by GE Energy

District
Power Generation and Heating
Cogeneration Plants
Offshore Applications

32
Gas Turbines Typical Loads

Centrifugal and Axial Electric Generators

Compressors
GE Energy
Gas Turbines

Reciprocating
Compressors Centrifugal Pumps

33
Nuovo Pignone

GAS TURBINES
OPERATING
PRINCIPLES

34
KEY TERMS

35
ISO conditions

Gas Turbine performance are declared in ISO condition and the

constructors have to declare fuel used to obtain declared performances.

36
ISO conditions

Ambient Pressure: 101.325 Pa (14,7 P.S.I.A.)

Ambient Teperature: 15 °C (59 °F)

Relative Humidity: 60%

Pressure drop in inlet/exhaust: 0 mm H2O

They are the conditions to refer for GT performances evaluation

37
FIRING TEMPERATURE

Section A refers the so called “TURBINE INLET TEMPERATURE”, wich is the average temperature of
hot gas at plane A.
Section C refers to the so-called “ISO FIRING TEMPERATURE”, wich is the average gas temperature at
plane C, calculated as a function of the air and fuel flow rates via a thermal balance of combustion
according to the ISO 2314 procedure.

38
FIRING TEMPERATURE
According to the NUOVO PIGNONE-GENERAL ELECTRIC standard, the
temperature that best represents point (3) is the one in section B

The difference in the interpretation of temperatures in section A

and B consists in the fact that the section B temperature takes T 3

account of mixing with 1st stage nozzle cooling air, wich was not
involved in the combustion process, but mixes with burnt gases 2
after cooling the surface of the nozzle. 4

P 2
S
3

4
1

V
39
PRESSURE RATIO

40
HEAT RATE

P 2 3 T 3

2
Q1
HR =
4

1 4 1

V S Lu
Heat Rate is the inverse of
2 efficiency, in that it indicates the
4
ratio between thermal energy,
3
resulting from the combustion
process, and mechanical energy,
1 obtained on the power shaft.

In generally expressed as kj/kWh

41
POWER & HEAT RATE
HEAT RATE

THERMAL ENERGY THAT WE SPEND TO

PRODUCE 1 UNIT OF MECHANICAL ENERGY

42
Power & Heat Rate
HEAT RATE

HEAT RATE IS THE

INVERSE OF
EFFICIENCY

43
Power & Heat Rate

If we think about a car,

HEAT RATE is…

MUCH MONEY FOR

LOW HEAT RATE
OUR COMPANY
44
Power & Heat Rate

HIGH POWER & LOW HEAT RATE

MUCH MONEY
FOR
OUR CUSTOMERS

45
COMPRESSOR RATIO

46
BRAYTON CYCLE
Fuel
Air Exhaust
1 Intake
4
CC
3 C - Compressor
2 CC - Combustion
C T L T - Turbine
L - Load

Combustion Expansion
P T 3
2 3

2 4

1 4
1
Compression Exhaust
V S

47
Specific Compression Work

Wc = c pm (T2 −T1 ) × (T2 − T1 ) Mesured in

Kj
kg inlet _ air
2
4

Cpm=average specific heat

1
at costant pressure

48
Specific Expansion Work

Wt = c pm (T3 −T4 ) × (T3 − T4 ) Mesured in

Kj
kg gas
2
4

Cpm=average specific heat

1
at costant pressure

49
Heat supplied to the combustion chamber

Q1 = c pm (T3 −T2 ) × (T3 − T2 ) Mesured in

Kj
kg gas
2
4

Cpm=average specific heat

1
at costant pressure

50
Heat suppl. to atmosphere with exhausted gas

Q2 = c pm (T4 −T1 ) × (T4 − T1 ) Mesured in

Kj
kg ehxaust _ gas
2
4

Cpm=average specific heat

1
at costant pressure

51
Thermodynamic efficiency

2
4

(Q1 − Q2 )
η cl =
1
Q1

This equation tell us that, by parity

of heat Q1, introduced into the
ηT = f (ηT ;ηC ;ηCC ;η cl ...) combustion chamber by fuel,
efficiency will increase as heat Q2
“dissipated” into the atmosphere
decreases

52
Useful work supplied to the driven machine

Pu = (Gair + G fuel ) × Wt − Gair × Wc

Kj
2
Measured in
4
s
3

Gair= amount of air

1

Gfuel= amount of fuel

53
MAIN PARAMETERS AFFECTING G.T. PERFORM.

In the Brayton Cycle the following parameters are

very important :
T 3

2
4

FIRING TEMPERATURE T3
1
PRESSURE RATIO P2
P1
P 2
S
3
THERMAL EFFICIENCY

SPECIFIC POWER Kw (kg )

s
4
1

V
54
Brayton Cycle: P1, P2

P1

P2
55
Brayton Cycle: T1, T2 and T3

T3=?

T1

T2
56
Brayton Cycle: T3

T3=f(T4,P2)

963°C
ß=10,5
(1765°F)

57
Brayton Cycle: T4

58
Single and Double shaft: differences to use

…PROBLEM IS IN THE AXIAL

COMPRESSOR OF HEAVY DUTY
GAS TURBINES…

59
G.T. for Generator Drive (mainly): Single shaft

60
Single shaft G.T. are preferred to drive Generators

SINGLE SHAFT GAS TURBINES MUST

ROTATE AT CONSTANT SPEED (i.e. 5100 rpm for
MS5001/6001, 3600 rpm for MS7001 and 3000 rpm for MS9001) TO
AVOID SURGE OR STALL PROBLEMS ON
ITS INTERNAL AXIAL COMPRESSOR

SINGLE SHAFT GAS TURBINES HAVE BEEN

MAINLY DEVELOPED TO DRIVE
ELECTRICAL GENERATORS BECAUSE THE
GENERATOR IS A MACHINE THAT NEEDS
TO ROTATE AT CONSTANT SPEED
61
Single Shaft G.T. Schematic

EXHAUST GAS
AIR
4
COMBUSTORS
COMBUSTIBILE
1 3
STARTING MOTOR

∼
2 LOAD
AXIAL
COMPRESSOR

AUXILIARY GEARBOX
TURBINE

60 MW 120 MW 60 MW
1-2 AIR COMPRESSION (50%) (100%) (50%)*
2-3 COMBUSTION *typical value for HD GT
3-4 EXPANSION

LOAD:
Electric Generator (often), Compressor, Pumps (rarely)
AUXILARY GEAR BOX
Drives Auxiliaries (mainly Oil Pumps) and transmits torque from Starting Device

62
Single Shaft Gas Tubines for GD
HEAVY DUTY Single Shaft G.E. Gas
Turbine Production Range
MS 1001 (*)
PGT 2 (*)
PGT5/1
GE 5/1
GE 10/1
MS 5001
MS 6001 (**)
MS 7001 (**)
MS 9001 (**)

(*) Out of production, Upgrade are available

(**) These units are also used in mechanical drive
applications where constant speed is required (i.e. LNG
SINGLE SHAFTS compression plants)

63
Gas Tubines for Mechanical Drive: Two shafts

64
Two shafts Heavy Duty type is better to drive loads
requiring speed changes infact …

IF WE NEED TO DRIVE….

65
Two shafts can provide high speed range variation..

…AS MS 5002, WHERE THE HP ROTOR

(ROTOR OF AXIAL COMPRESSOR)
CONTINUE TO WORK AT CONSTANT SPEED
(5.100 rpm),

WHILE THE LP ROTOR (ROTOR DRIVING

THE LOAD) CAN CHANGE ITS NOMINAL
SPEED (100% = 4.670 rpm)
IN THE RANGE OF
50% (2340 rpm) TO 105% (4900 rpm)
66
Two Shafts G.E. G.T. Schematic
VANES OF VARIABLE
AREA NOZZLE
COMBUSTOR(s) EXHAUST
PT
GG
STAGES GAS
STAGES
AIR INLET
LOAD

FROM STARTING ENGINE

α
AXIAL
COPRESSOR
TO AUXILIARY
GEAR BOX

POWER
GAS GENERATOR TURBINE
(GG) (PT)

Gas Generator (GG) turbine drives axial compressor and turbine auxiliary by means of gearbox.
Power Turbine (PT) drives the load, usually a centrifugal compressor or a pump, rarely an electric
generator.
PT e GG works at different speed.
GG speed is constant during normal operation.
PT speed can change in the range 50-105% of its rated speed during operation.
The PT first nozzle is composed of variable vanes. In this way, by varying the angle α of the vanes, it’s
possible to manage the power sharing between GG and PT by the speed control of the two rotors.

67
Speed/Load control in Two shafts G.E. HD GT
IN THE G.E. H.D. TWO SHAFT GAS TURBINES, AS THE MS 5002, IN
ORDER TO CONTROL THE SPEED OF HP AND LP ROTOR, A SECOND
STAGE VARIABLE NOZZLE SYSTEM IS USED

68
G.E. HD Two Shafts GT: 2nd st.Variable Nozzles

Opened Variable Nozzle :

Lowest Pressure Drop on
the nozzle, i.e. HP Turbine
lowest back pressure

69
G.E. HD Two Shafts GT: 2nd st.Variable Nozzles

Closed Variable Nozzle :

Highest Pressure Drop on
the nozzle, i.e. HP Turbine
maximum back pressure

70
Two Shafts Gas Tubines for MD

HEAVY DUTY Two Shafts G.E.

MS 1002 (*) (*) Out of production, Gas Turbine Production Range
Upgrade are available
PGT5/2
(**) New model
GE 5/2 (**)
(***)
PGT 10/2
GE 10/2
MS 3002 (*)
MS 5002

some GE Single Shaft Gas Turbine can be used

for MD applications. in special process as LNG,
Methanol, etc

MS 6001, MS 7001, MS 9001

71
Heavy Duty G.T. G.E. Supply Chain

Firenze ( I ) Greenville ( U.S.A.) Belfort ( F )

Machine GT MW Machine GT MW Machine GT MW

GE5 5.5 7E 85 6FA 70

172 123
7FA 9E
GE10 11

400 (CC) 9FA 255

7H
FR5 30
255 6B 42.2
9FA

9H 500 (CC)

72
Nuovo Pignone

HEAVY DUTY
GAS TURBINES

COMPONENTS
DESCRIPTION
AND
MAIN FEATURES
73
Inlet Section Gas Turbine

Inlet casing:
- directs the flow of outside air from the air inlet
equipment into compressor blading
- Variable Inlet Guide Vane assembly
- N°1 bearing assembly
- Thrust bearings, active and inactive
- Low pressure air seals

74
Gas Turbine Axial Compressor

75
HD GT Axial Compressor Operation

COMPRESSOR
is the part of the
engine where air
is compressed

Compressor Discharge:
(1) 30% is used for primary air (combustion air)
(2) 5% is used to operation of gas turbine accessories:

-bleed air and seal air

-gas turbine start and motor air
-gas turbine anti-icing

(3) Remainder is used as secondary air to:

- cool combustion gases
- Provide film cooling of the gas generator turbine

76
HD GT Axial Compressor Operation

77
HD GT Axial Compressor Design
AIR

Journal BEARING
DISCS TENSION RODS
IGV

Airfoils with large thicknesses

Rotor stage discs linked by thick tension rods.
Sliding Journal bearings
Compressor Variable Inlet Guide vanes (IGV)
(to control the air flow)

78
HD GT Axial Compressor Design

79
HD GT Axial Compressor Design

80
HD GT Axial Compressor Design

Random blades are

selected for an automated
check for the curvature,
thickness, width and so
farth.

81
HD GT Axial Compressor Assembly

Compressor Wheels:
Rotor blades are inserted into
these slot and held in axial
position by spacer pieces,
which are in turn staked at
each end of slot

82
HD GT Combustion Chamber(s) Operation
COMBUSTOR(s)
is the part of the engine
where air is mixed with
fuel and burned with a
portion of the
compressor air

The combustion 30%

casing allows
compressor discharge
air to be directed
through the flow sleeve
30%
and ultimately into the
combustion liner
40%
83
HD GT Combustion Chamber Design
COVER SPARKLING PLUG
LINER COMBUSTION CHAMBER WRAPPER

GAS FUEL

LIQUID FUEL REACTION

DILUITION ZONE EX
ZONE HA
US
TG
AS
BURNER

COMBUSTION AIR PORT

GAS CONVEYOR
SLOTS OR HOLES FOR THE LINER COOLING AIR AIR FROM THE AXIAL COMPRESSOR
“TRANSITION PIECE”

- The air flow through the combustion chamber has three functions: oxidize fuel,
cool the metal parts, condition the extremely hot combustion products to the
desired turbine inlet temperature.
- The air enters the combustion chamber and flows forward, entering the liner
through holes and louvers in the liner wall.
- A portion of the air reaches the head end of C.C. and enters the liner through
the cap where the axial swirler creates a vortex.

84
NOx reduction for Heavy Duty Gas Turbines
DRY Systems WET Systems

1) Steam Injection* This system

consists of the injection of atomized steam
DLN 1: in the combustion chamber to decrease
flame temperature and so NOx.
Dry Low
NOx. • Easy to install
• Requires Steam
• Increases maintenance

2) Water Injection * This system

consists of the injection of atomized water
in the combustion chamber to decrease
flame temperature and so NOx.
• Easy to install
DLN 2:
• Requires water
Dry Low NOx.
• Increases maintenance

* Appliable for all GE HD GT

85
HD GT Turbine Section

TURBINE
is the part of the
engine where the hot
gases flowing from
the combustor
produce the
mechanical power

The turbine can consist of several stages. Each

stage is comprised of stationary row of nozzles
where the high energy gases are increased in
velocity and directed toward a rotating row of
buckets, or airfoils, attached to the turbine shaft.

As the gas flows through the turbine rotating shaft,

the gas kinetic energy is converted into horsepower.

86
HD GT Turbine Section Operation

87
HD GT Turbine Section Design
Rotor blades (“Buckets”) and stator nozzles with
large thickness, with high corrosion and erosion
resistance.
They can accept also heavy fuel oil (residual
treated oil), but with more frequent maintenance
intervals.

ROTATION AXIS

88
HD GT Turbine Sec. Manufacture & Assembly

…after the casting process,

machining and grinding is
done to the dovetail and to
the sealing wings….

89
HD GT Turb.Sec. Blades Manuf. & Assembly

…the bucket is then given a

first and second coating…

…the last step before

shipping is to give to each
bucket a weight and a
serial number.

90
HD GT Turbine Section: Nozzles Design

In the turbine there are stationary

nozzles which direct the high-velocity
flow of the expanded hot combustion
gas against the turbine buckets
causing the turbine rotor to rotate.

91
HD GT Turbine Section: Nozzles Design

92
HD GT Turbine Section : Seals Design
Unlike the compressor blading, the turbine bucket tips do not
run directly against an integral machined surface of the casing
but against annular curved segments called turbine shrouds.

93
HD GT Exhaust Section

Exhaust casing:
- the frame consist of an outer cylinder and an inner cylinder
interconnected by radial struts.
- directs the flow of hot gas coming from the turbine section into the
exhaust duct
- Turing Vanes are installed to reduce hot gas path turbolence / losses

94
HD Gas Turbine Bearings

The gas turbine unit contains two/three or four main journal bearings,
[depending on if the unit is single or two shafts type] used to support the
gas turbine rotor. The unit also includes thrust bearings to maintain the
rotor-to-stator axial position and to support the thrust loads developed
on the rotor. These bearings and seals are incorporated in two, three or
four housing, depending on the bearing number.

The GT bearings are pressure-lubricated by a fluid (oil) supplied from

the lubricating system.
The fluid flows through branch lines to an inlet port provided in each
bearing housing.

95
HD Gas Turbine Journal Bearings
Type:

Elliptical

96
HD Gas Turbine Thrust Bearings

Type:
Load (Equalizing)
Unloaded (Non-Equalizing)

97
Gas Turbine: Thrust Loads on Bearings
(Example for a single shaft G.T.
only)

Start-up and Shutdown

Thrust is given by the prevalent
action of the compressor load
since in the turbine there is no gas
expansion (turbine load gradualy
increases starting from flame-on).
In the same way, turbine reduces
its thrust following the power Load on
reduction, till the flame out, during
shut-down. Inactive Thrust Bearing

Normal Operation
Thrust given by the action of
the turbine becomes
prevalent, respect to that one
of the compressor, starting
from flame-on and rising with
the turbine load increasing
(turbine power is about 200% Load on Thrust action direction, on the G.T. Bearing,
of compressor power). changes during starting and loading sequence due
Active Thrust Bearing to the increased load on the turbine.
It happens, therefore, in the opposite sequence
during shut-down, because of turbine power
decreasing. 98
G.T PERFORMANCES: Influence Factors

EXTERNAL FACTORS

EXTERNAL FACTORS

• AMBIENT TEMPERATURE
• AMBIENT PRESSURE
• RELATIVE HUMIDITY
• GAS FUEL PROPERTIES

INTERNAL FACTORS

• PRESSURE DROP IN THE INTAKE SYSTEM

• BACKPRESSURE IN THE EXHAUST SYSTEM

• AXIAL COMPRESSOR CLEANLINESS

99
Effects of Amb. Temper. on P, HR, AF/EF

Press. ratio ⇓ Exh. Temp. ⇑

If Tamb⇑ Air Flow ⇓ Heat rate ⇑
Power Output ⇓

100
Effects of Amb. Temp. on Exh. Temp

101
Effects of Amb. Temp. (Part Load with Modulat. IGV)

Exhaust Temperature vs.

Output Percent:
VIGV Control Mode

Exhaust Flow vs. Output

Percent:
VIGV Control Mode

102
Effects of Ambient Pressure

Pr. ratio ⇔
If pamb ⇓ Exh.Temp. ⇔
Air Flow ⇓
Heat rate ⇔
Power Output ⇓
103
Effects of Ambient Humidity

Mass flow ⇓
If rH ⇑ Heat Rate ⇑
Power Output ⇓
104
G.T PERFORMANCES: Influence Factors
INTERNAL FACTORS

EXTERNAL FACTORS

• AMBIENT TEMPERATURE
• AMBIENT PRESSURE
• RELATIVE HUMIDITY
• GAS FUEL PROPERTIES

INTERNAL FACTORS

• PRESSURE DROP IN THE INTAKE SYSTEM

• BACKPRESSURE IN THE EXHAUST SYSTEM

• AXIAL COMPRESSOR CLEANLINESS

105
Pressure drops effects on air intake system

INTAKE SYSTEM
Pressure drop in the intake system is caused by the friction of air
flow through the silencers, and by the change in direction of the
air path along the intake ducting.
Pressure drop causes loss of power (similar to the altitude effect)
and the increase of specific fuel consumption (Heat Rate).

106
Pressure drops effects on Air Intake system

p 1'

p 1' = p 1 − ∆p

∆p = pressure drop

Pr. Ratio ⇔
Exh. temp. ⇑
∆p = pressure drop ⇑ Mass flow ⇓
Heat rate ⇑
Power Output ⇓

107
Pressure drops effects on Exhaust system
Backpressure in the exhaust system comes from the same mechanism of intake
pressure drop, with the addition of the pressure drop due to the boiler, in case of a
combined cycle.
The increased back pressure reduces the expansion rate and the relevant amount of
energy given by the turbine section.
As for the intake losses, this causes loss of power and increase of specific fuel
consumption (Heat Rate).

108
Backpressure effects on Exhaust system

p 4'

p 4' = p 4 + ∆p

∆p = pressure drop

Pr. ratio ⇔
Exh. temp. ⇑
∆p = pressure drop ⇑ Mass flow ⇔
Heat rate ⇑
Power Output ⇓

109
G.T PERFORMANCES: Influence Factors
COMPRESSOR CLEANING CONDITIONS

110
Performance Calculation Exhample
ISO CONDITIONS (MS7001) SITE CONDITIONS

Temperature (°C) 15 Pressure (mbar abs) 989

Pressure* (mbar abs) 1013 Temperature (°C) 30
Output power*** (ISO kW) 85400 Inlet system ∆p (mm H2O) 100
Heat Rate ***(kj/kWh) 10990 Exhaust system ∆p (mm H2O) 100
Turbine speed (100% RPM) 3600

CORRECTION FACTORS

Fpressure = 989/1013 = 0.977

**
**From
FromTemperature
Temperature correction
correctioncurve
curve FkW- temperature ** 0,90
FkWInlet system ∆p *** = (100-1,7)/100 = 0,983
FkWExh system ∆p *** = (100-0,6)/100 = 0,994
***
***From
Fromperf.
perf.curves
curvesdesign
designdata
dataand
andnotes
notes FHR- temperature ** 1,020
FHR- Inlet system ∆p *** = (100+0,45)/100 = 1,0045
FHR- exh system ∆p *** = (100+0,5)/100 = 1,005

Site Output Power (kW) = ISOkW x 0.977 x 0,90 x 0,983 x 0,994 = 85400 x 0,86 = 73444

Site Heat Rate (kj/kWh) = Design HR x 1,020 x 1,0045 x 1,005 = 10990 x 1,029 = 11308

Site Heat consumption (Kj/s) = Site Output Power x Site HR = 73444 x 11308 / 3600 = 230710

Site thermal efficiency (%) = 3600/ Site Heat Rate = (3600/ 11308) x 100 = 31,80

111
PERFORMANCE ENHANCEMENT METHODS

1) Cooling inlet air Inlet Temperature

2) Steam and Water Injection Increase mass flow

3) Peak Load Fire Temperature

WARNING
!!
112
Inlet Cooling

113
Inlet Cooling: Evaporative Cooler Schematic

114
Inlet Cooling : Application Field

115
Inlet Cooling : System Balancing Care

116
Evaporative Cooling Vs. Inlet Chilling

117
Steam / Water Injection
Water Rates vs. Air Flow for Power Augmentation

118