General Power present 1.pdf

1Chander, Sailesh

Power Plants

GAS TURBINES

or

COMBUSTION TURBINES

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2Chander, Sailesh

1

2

8

7

6

5

43

Design Features

(1) GeneratorCoupling

(2) Casing(3) Rotor(4) Compressor

(5) Combustion System

(6) Burners(7) Turbine(8) Exhaust

Not Designed to Fly !

Not Designed to Fly !




3Chander, Sailesh

GT and Generator and Auxiliaries

R

21

3 4




4Chander, Sailesh

435 C (815 F)19.7 bara (286 psia)

128 kg/s (282 lb/s)15 C (59 F)1.013 bara (14,7 psia)

130,4 kg/s (287 lb/s)538 C (1001 F)1.013 bara (14.7 psia)

SGT-800, ISO data (simple cycle)

2.6 kg/s fuel (5.7 lb/s)

1180 C (2156 F)18.7 bara (271 psia)

TITmixed (ISO2314) 45 MW, 37 %




5Chander, Sailesh

Reaction Turbine blades & vanes

Blade #1

Vane #1

Blade #2

Vane #2Vane #3

Blade #3

Flow direction, combustion gas

Inco 792Coating SV349TBC on platforms

CMSX4Coating CN 91

Inco 738Coating Sermalloy JTBC on platforms

Inco 792

Inco 939

Inco 792




6Chander, Sailesh

Brayton Cycle - GT

P

V

1 4s 4

2s 2 3 T

s

1

4s4

2s

3

2

1-2s : compressor- compressed adiabatic reversible*, no heat exchanged (isentropic)2s-3 : combustor heated at const pressure3-4s: turbine expanded adiabatic reversible* (isentropic)4s-1: exhaust /HRSG cooling at const pressure *ideal case, same entropy (s)

400 C

1200 C

550 C

30 C ambient

12 bar a

1 bar a




7Chander, Sailesh

Increasing GT Efficiency

Net Turbine Power = Turbine power Compressor Power

= mc[ (T3 T4) (T2-T1)] --------------a m=flow rate, c =Spec heatFuel in = mc[T3 - T2] ----------------------------------b

Efficiency = b / a or T4 T4 T2 + T1T2 + T1 so try to increase T3 and T2T3 - T2

T3 (firing temp) = increase fuel flow into combustor T2 (compressor outlet temp) = increase compressor ratio or sealing




8Chander, Sailesh

Efficiency

Compressor Pressure ratio rp

Increasing GT Efficiency increasing compressor Ratio




9Chander, Sailesh

36

34

32

30

[%]

Effic

ien

cy

16014012010080

[MW]

Pow

er

ou

tpu

t

800 900 1000 1100TT1 ISO

V94.0, V94.1 V94.2

10501060

1075

1974 1981 2002

930

V94.2(1)V94.2(2)

V94.2(3)

V94.2(6)

EVOLUTION OF THERMODYNAMIC PERFORMANCE V94.2




10Chander, Sailesh

Operating Profile Germany Winter day

GT

CCPP

Nuclear /Coal/Hydro




11Chander, Sailesh

The Market Conditions Have Changed Dramatically in the Power Industry Over the Last 10 Years

Mar

ket C

on

ditio

ns

Years

Risk Guaranty*

Price

Overall Construction Time

Efficiency

* technical warranties, delivery time




12Chander, Sailesh

One SGT5-8000HGas Turbine

340 MW

4 xBoeing 747Jumbo Jet

1.5 Million pop.City like KL

Power Comparison MW Basics




13Chander, Sailesh

Programme for Scheduled Inspections Econopac

Time of Operation**Year

after PAC 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.Systems EOH 8,300 16,600 25,000 33,300 41,600 50,000 58,300 66,600 75,000 83,300 91,600 100,000

Gas TurbineGenerator

Type of inspection

= Initial inspection

= Major inspection

= Minor inspection

= Hot gas path inspection= Medium inspection

Duration of Maintenance Offer +)

**) with average 8,300 EOH per year

+) This figure is to be reduced by num-ber of EOH accumulated before PAC

V94.2 (33,000EOH) Cycle

Typical Inspection Schedule Overview




14Chander, Sailesh

Minor Inspection Accessibilities of a V94.2 Gas Turbine




15Chander, Sailesh

Maintenance actions

Action

Remove upper casing half, upper and

lower half of turbine blade

carrier

Hot Gas Path Inspection

Action

Disassemble the machine with the rotor remaining in

the bearings

Major Inspection

Minor Inspection

Action

Openmanhole




16Chander, Sailesh

Hot Gas Path Inspection of V94.2 Gas Turbine

Activities

Disassembly of the gas turbine (without compressor)Replacing of turbine stationary blade assemblies

Replacing of turbine stationary blades stage 1- 2 (V94.2)

Replacing of turbine moving blades stage 1- 3 (V94.2)

Combustion chamber inspection




17Chander, Sailesh

Major Inspection of V94.2 Gas Turbine

Activities

Complete disassembly of the gas turbine (excl. removal of rotor)

Removal and inspection of compressor stationary blade assemblies and turbine stationary blade assemblies

Replacing of turbine stationary blades stage 1-2 (V94.2)

Replacing of turbine moving blades stage 1-3 (V94.2)

Combustion chamber inspection

Inspection according to checklist




18Chander, Sailesh

Case 1: Gas Turbine in Simple Cycle

100 % fuel

Gas Turbine

63.6 % losses

36.4 % electricity

Pgt 44.30 MW Pst 0 MW Paux 0.10 MW Pnet 44.20 MW Heat duty 0 MJ/s Qfired 121.4 MJ/s

Alfa --- Net electrical efficiency 36.4 % Net total efficiency 36.4 %




19Chander, Sailesh

Plants

CCPP - Combined Cycle Power Plants




20Chander, Sailesh

Sankey-Diagram

3_3_0_0_4/a PG W71

GUD =264 + 138

689 100 = 58.4 %

Stack gas56 MW 8.13 %

Condenser227 MW 32.95 %

Auxiliariesand losses

4 MW 0.58 %

Steam turbine output138 MW 20.03 %

Gas turbine output264 MW38.32 %

Auxiliaries and losses

2 MW 0.29 %

Turbine532 MW77.2 %

Compressor266 MW38.6 %

Exhaust gas425 MW61.68 %

Fuel 689 MW 100 %




21Chander, Sailesh

Steam Turbine (condensing)

100 % fuel

15 deg CGas Turbine

Case 2: Gas Turbine in Combined Cycle

2-pressure HRSG

520 deg C

27 deg C

31 deg C31 deg C

12 % losses

35.9 % electricity

16.8 % electricity

35 % lossesPgt 43.69 MWPst 20.78 MWPaux 0.70 MWPnet 63.77 MWHeat duty 0 MJ/sQfired 120.9 MJ/s

Alfa ---Net electrical efficiency 52.7 %Net total efficiency 52.7 %




22Chander, Sailesh

Combined Cycle Configurations

Multi shaft 1 on 1, 2 on 1, 3 on 1

Single Shaft (1 GT 1 ST and 1 Gen shared)




23Chander, Sailesh

Combined Cycle Reference Power Plants

Multi Shaft >

< Single Shaft




24Chander, Sailesh

Typical Cycle Design for V94.2 GUD Multi- Shaft Block with Dual-Pressure Steam Cycle

Feed water-tank anddeaerator

HRSG2

HRSG2

HRSG2

HRSG2

HRSG

Exhaustgas

Air

Gasor Oil

HRSG2

G~

G~

economiser

evap

superheater




25Chander, Sailesh

Rankine Cycle Combined Cycle Single pressure

T

s

1

3

2

4

6

7

8

95

5-6 : Pumped6-7 :Economiser7-7 : Evaporator /drum7-8: Superheater8-9 : Expansion in ST9-5 : Condenser

7




26Chander, Sailesh

3_4_3_0_16 KWU G11

TransformerAir IntakeGeneratorGas turbineDiffuser

Heat-Recovery Steam Generator

Stack

50 m (164 ft)

Area for Power plant: 200m L x 60m W




27Chander, Sailesh

Scope

CONFIGURATION: 1 Block of 1-on-1 Combined CycleSCOPE OFFERED - Full EPC of Plant comprising of:

2 x GEN set (air cooled) 1 GT V94.2 with auxiliaries 1 ST dual pressure with auxiliaries 1 x HRSG Dual Pressure 2 x HV 500kV Transformers Civil Works complete with Turbine Hall, waste water drainage and management Electrical BoP (Emergency Diesel Set, Lighting, Communications, protection etc) 500kV Switchyard Mechanical BoP (HVAC, cranes, fire fighting, electro chlorint,

water treatment , dosing etc.) Cooling Water (sea) System (Once Through) Instrumentation and Control Transportation Engineering Proj Mgmt, Erection & Commissioning Spares & Basic Consumables till COD Documents Basic Training




28Chander, Sailesh

2_1_0_0_10 KWU G11

Structures/system (25-28mths) Month no.2 4 6 8 10 12 14 16 18Contract awardCivil worksCrane (ST building)Heat-recovery boiler (1 HRSG)Acid cleaningWater/steam cycleCirculating-water equipmentSteam turbine / condenserGenerator STOil flushing STGas turbine / generator unit 1(Gas turbine / generator unit 2)Oil flushing GTComm.: gas turbine 1 and 2I&C/Electrical equipmentTransformerComm.: HRSG, ST, water/steam cycleTrial run

20Site activities

22 24

1.Ignition GT1

CW systemCW pipes

1.steam




29Chander, Sailesh

Thanks a lot for your attention !ANY QUESTIONS ?




Gas Turbines & Combined Cycle PlantsChander, SaileshUNITEN, 26.01.2006

Power PlantsGAS TURBINESCOMBUSTION TURBINES

Design Features(1) Generator Coupling(2) Casing(3) Rotor(4) Compressor(5) Combustion System(6) Burners(7) Turbine(8) ExhaustNot Designed to Fly !

GT and Generator and AuxiliariesSGT-800, ISO data (simple cycle)45 MW, 37 %

Reaction Turbine blades & vanesBlade #1Vane #1Blade #2Vane #2Vane #3Blade #3Inco 792Coating SV349TBC on platformsCoating CN 91Inco 738Coating Sermalloy JTBC on platformsInco 792Inco 939Inco 792

Brayton Cycle - GT2s 21-2s : compressor- compressed adiabatic reversible*, no heat exchanged (isentropic)2s-3 : combustor heated at const pressure3-4s: turbine expanded adiabatic reversible* \(isentropic\)4s-1: exhaust /HRSG cooling at const pressure*ideal case, same entropy (s)400 C1200 C550 C30 C ambient12 bar a1 bar a

Increasing GT EfficiencyNet Turbine Power = Turbine power Compressor Power= mc[ \(T3 T4\) \(T2-T1\)] --------------a m=flow rate, c =Spec heatFuel in = mc[T3 - T2] ----------------------------------bEfficiency = b / a or a T3 T4 T2 + T1 so try to increase T3 and T2T3 - T2T3 (firing temp) = increase fuel flow into combustorT2 (compressor outlet temp) = increase compressor ratio or sealing

Compressor Pressure ratio rpIncreasing GT Efficiency increasing compressor Ratio

EVOLUTION OF THERMODYNAMIC PERFORMANCE V94.2Operating Profile Germany Winter dayNuclear /Coal/Hydro

The Market Conditions Have Changed Dramatically in the Power Industry Over the Last 10 YearsMarket Conditions* technical warranties, delivery time

Gas Turbine340 MW4 xBoeing 747Jumbo Jet1.5 Million popCity like KLPower Comparison MW Basics

V94.2 (33,000EOH) CycleTypical Inspection Schedule Overview

Minor Inspection Accessibilities of a V94.2 Gas TurbineMaintenance actionsHot Gas Path Inspection of V94.2 Gas TurbineDisassembly of the gas turbine (without compressor)Replacing of turbine stationary blade assembliesReplacing of turbine stationary blades stage 1- 2 (V94.2)Replacing of turbine moving blades stage 1- 3 (V94.2)Combustion chamber inspection

Major Inspection of V94.2 Gas TurbineComplete disassembly of the gas turbine (exclRemoval and inspection of compressor stationary blade assemblies and turbine stationary blade assembliesReplacing of turbine stationary blades stage 1-2 (V94.2)Replacing of turbine moving blades stage 1-3 (V94.2)Combustion chamber inspectionInspection according to checklist

Case 1: Gas Turbine in Simple Cycle100 % fuelGas Turbine

CCPP - Combined Cycle Power Plants PG W71h GUD =264 + 138 100 = 58.4 %Stack gas56 MW 8.13 %Condenser227 MW 32.95 %Auxiliariesand losses4 MW 0.58 %Steam turbine output138 MW 20.03 %Gas turbine output264 MW38.32 %Auxiliaries and losses2 MW 0.29 %Turbine532 MW77.2 %Compressor266 MW38.6 %Exhaust gas425 MW61.68 %Fuel 689 MW 100 %

Steam Turbine (condensing)100 % fuel15 deg CGas TurbineCase 2: Gas Turbine in Combined Cycle2-pressure HRSG520 deg C27 deg C31 deg C31 deg C

Combined Cycle ConfigurationsMulti shaft 1 on 1, 2 on 1, 3 on 1Single Shaft (1 GT 1 ST and 1 Gen shared)

Combined Cycle Reference Power PlantsMulti Shaft >< Single Shaft

Typical Cycle Design for V94.2 GUD Multi- Shaft Block with Dual-Pressure Steam CycleFeed water-tank andExhaustgasGasor OilG~G~

Rankine Cycle Combined Cycle Single pressure5-6 : Pumped6-7 :Economiser7-7 : Evaporator /drum7-8: Superheater8-9 : Expansion in ST9-5 : Condenser7

KWU G11Air IntakeGas turbineHeat-Recovery Steam Generator50 m (164 ft)Area for Power plant:200m L x 60m W

CONFIGURATION: 1 Block of 1-on-1 Combined CycleSCOPE OFFERED - Full EPC of Plant comprising of:2 x GEN set (air cooled)1 GT V94.2 with auxiliaries1 ST dual pressure with auxiliaries1 x HRSG Dual Pressure2 x HV 500kV TransformersCivil Works complete with Turbine Hall, waste water drainage and managementElectrical BoP \(Emergency Diesel Set, Lighting, Communications, protection etc\)500kV SwitchyardMechanical BoP \(HVAC, cranes, fire fighting, electro chlorint, water treatment , dosing etc.\)Cooling Water (sea) System (Once Through)Instrumentation and ControlProj Mgmt, Erection & CommissioningSpares & Basic Consumables till CODBasic Training

KWU G11

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