lms100 gas turbine system - tradekeyimg.tradekey.com/images/uploadedimages/brochures/0/4/1244147...2...

GE Energy

LMS100® Gas Turbine System”A flexible growth platform to meet changing energy needs.”

2 /LMS100 Gas Turbine System /

11/5/2009

LMS100

LM6000

LMS100

LM6000

LM6000

Sprint® Intercooling

CFM TECH56

CAPPs Combustor

Advanced Controls

MK VIe, Smart Sensors

Synthetic Logic

The LMS100 … game changing technology from frame and aero gas turbines

• 100MW

• 44-50% efficiency

• High part power efficiency

• Cyclic capability

• 10 minute starts

• Load following abilityGE90

High Pressure Ratio (42:1)

F/H Technology

CompressorHeat Exchanger

Packaging


11/5/2009

MS6001FALow Pressure Compressor (LPC)

Intermediate Pressure Turbine (IPT)

Exhaust Diffuser

Power Turbine (PT)

Power Turbine Shaft

Intercooler System

CF6-80C2High Pressure Compressor (HPC)

CF6-80EHigh Pressure Turbine (HPT)

Single AnnularCombustor (SAC)(DLE not shown)

Combining the best of both worlds


11/5/2009

Modular gen-sets

Scene 4 cont:

• The intercooler system reduces the workload of the

high-pressure compressor. Less workload equals

increased power outputs and better overall efficiency.

The end result is outputs above 100MW with simple

cycle thermal efficiencies in excess of 46% -- an

astounding 10% increase over our most efficient

competitors.

• CALLOUT : 10% efficiency increase over the

compeition.

• Comments: showing constant airflow cycle as camera

pans around entire plant13

14 15

Simple Cycle ExhaustGT Driver Package

Cooling Tower

MS6001FA Inlet System

Variable BleedValve (VBV) System

Air to WaterIntercooler

Dual RatedGenerator


11/5/2009

Typical plant arrangement

Cooling Tower

Power Control Module

Gas Fuel Heater

50 m

50 m


11/5/2009

50Hz Configurations / Applications*

SAC-Water DLE SAC-STIG DLE-CC***

Gen Terminal Plant, MW 102.8 99 110.8 116

Gen Terminal Heat Rate, KJ/KWH LHV 8,173 7,921 7,263 6,700

NOX Emissions, mg/Nm3** 50 50 50 50

• Hot day power

• 10 minute starts

• Fast load response

Flexible power with high efficiency

AssumptionsAltitude sea level * 50 Hz, Rated Power, Average Engine HR, Methane Fuel, Rounded Values, Temperature / Rel. Humidity 15oC/60% Excludes Intercooler Fan LossNo Inlet / Exhaust Losses ** 15% O2, Without SCR, Natural gas

*** Inlet / Exhaust losses = 101.6mm / 381mm H2O

• Part power efficiency

• Lower mass emissions

• Modular maintenance

WITH


11/5/2009

“Game changing” power and efficiency in cycling duty segment

30%

32%

34%

36%

38%

40%

42%

44%

46%

48%

50%

60,000 80,000 100,000 120,000 140,000 160,000 180,000 200,000

GT Output (kW)

Sim

ple

Cy

cle

Eff

icie

ncy

7EA

GT11NM

M501

GT11N29E

M701V64.3A

6FA

7FA

GT13E2

M501F

W501D5A

V94.2

SAC w/water

DLE

SAC w/steam

STIG

10% Improvement over best available


11/5/2009

Great hot day performance


11/5/2009

10 Minute starts to full power

XN25

0

2000

4000

6000

8000

10000

0 200 400 600 800 1000 1200 1400 1600 1800 2000

Time (sec)

XN

25 (

RP

M)

XN25

Dry

mo

tor

/ p

urg

e

Ign

itio

n

Accel

to S

I

Syn

c id

le

Decel to

min

id

le

Sh

ut

do

wn

Accel

to m

ax

Wate

r o

n a

t ~

30M

W

Min

id

le

Co

old

ow

n


5/3/2005

Aero gas turbines are designed to cycle

120 sec accel & decels

<8 sec to

max power

Thrust

Reverse

Cruise

climb

Typical Aircraft Engine Transient

Typical Aeroderivative

Industrial Engine Transient

High strength alloys, lighter sections

Designed for cyclic life

No start cycle penalty for

maintenance intervals


11/5/2009

50MW in less than a minute


11/5/2009

Replaceable“Supercore”(24 Hr change out)

(All maintenance interval same as LM6000)

Maintenance Intervals:Hot Section - 25,000 HrsOverhaul - 50,000 Hrs

Rotable Modules:- Combustor- HPT- IPT- PT

Total down time < 4 days with rotables

“LM” modular maintenance philosophy


11/5/2009

Rotable modules for onsite overhauls …

Combustor HPT IPT

Typical HPT Rotable Workscope

Tear down rotor & stator

Repair / replace S1 blades, S1N, S2

blades & S2N

Balance / repair stator

Replace stator shrouds

High speed grind HPT rotor to match

fit with stator

HPC TMF


11/5/2009

Typical Aero Service Intervals

Interval Scheduled Maintenance Action Outage Duration

4,000 hours (every 4K h) Borescope Inspection (includes cool-down time) 12 hours

25,000 hours Hot Section Interval*

1) On-Site Hot Section Replacement (Combustor, HPT, IPT)

4 days(a)

50,000 hours Depot Maintenance(b)

1) Major Hot Section Overhaul (Combustor, HPT, IPT)

2) Inspect Booster, Intercooler, Scroll Frames, HPC, Aft Shaft & Bearings

(c)

3) Power Turbine Overhaul

4 days(a)

75,000 hours Hot Section Interval(b)

1) On-Site Hot Section Replacement (Combustor, HPT, IPT)

4 days(a)

100,000 hours Depot Maintenance(b)

1) Major Hot Section Overhaul (Combustor, HPT, IPT)

2) Inspect Intercooler, Scroll Frames, HPC, Aft Shaft & Bearings(c)

3) Power Turbine Overhaul

4) Booster & Shaft Inspection/Maintenance

4 days(a)

(a) Rotable module installed during maintenance period

(b) Lease/spare “supercore” and Power Turbine modules are installed during maintenance period. For depot maintenance, outage duration is 60 days if no spare/lease module(s) are used.

(c) Roller and ball bearings are replaced at 50,000 hours; hydrodynamic bearings are inspected.


11/5/2009

Potential for >90% CHP efficiency utilizing intercooler and exhaust energy

Intercooler

200

300

400

0 20 40 60 80 100 120

Inlet Temperature (F)

I/C

Te

mp

era

ture

, (F

)

-10 0 10 20 30 40

Degrees C

Deg

C

100

150

20050 Hz

60 Hz

700

720

740

760

780

800

820

0 20 40 60 80 100 120

Inlet Temperature (F)

Ex

ha

us

t T

em

pe

ratu

re, (F

) -10 0 10 20 30 40

Degrees C

Deg

C

380

400

420

50 Hz

60 Hz

HRSG

~25-30 MWT ~70-80 MWT


11/5/2009

Value in all applications

Application Capability / Benefits

• Simple Cycle peaking Cyclic ability with low maintenance and installed cost

• Simple Cycle Mid-range dispatch High efficiency/low installed cost

• Combined Cycle Small steam plant @ 54%

• CHP – steam to process High power/steam ratio Flexibility – power or process steam

• CHP – District Heating >90% efficiency – max energy use

• Coal Plant Feed Water Heating 57-60% gas to electric conversion


11/5/2009

LMS100 makes feed water heating applications extremely attractive

• High gas energy to electricity conversion > 47-54% for sub-critical repowering

applications

> 57-60% for new super-critical applications

• Project costs lower than combined cycle GT

• Integrated plant part power flexibility

• Lower plant emissions


11/5/2009

Low pressure compressor

MS6001FA17 Stage Compressor >8 Million hours of operation

LMS100 LPC- 1st 6 Stages of 6FA Compressor - Same operating speed - Same flow, pressure and temperature - Variable speed operation

LMS100 LPC


11/5/2009

Core – high pressure rotor

Introduced - 1985Operating hours >100 million

CF6-80C2/E

Introduced - 1991Operating hours > 9,000,000

LM6000

LMS100 Core- HPC derived from CF6-80C2

- HPT derived from CF6-80E

- Lower shaft speed

- Lower T3

- Increased firing temperature


11/5/2009

LM6000

LMS100

LMS100 Design

• Design basis … LM6000• Same CRF Volume & Diffuser• Areas Redesigned for Operability &

Performance:- Fuel Nozzle

- Swirler

- Liners

• Areas Redesigned for Reliability Improvements:

- Fuel Nozzle

- Swirler / Ferrule

- Splashplate

- Domeplate Cooling pattern

- Venturi

Standard Annular Combustor (SAC)


11/5/2009

2-stage turbine

Same hot flowpath and materials as LM6000

Based on CF6-80C2/E “boltless rotor” design with over 500,000 EOH

Increased flow capability

Operating Conditions (vs LM6000)- Pressure ratio 30% lower…………………...lower stress - Cooling temperatures 250F colder- Cooling flow higher …Same metal temperature - T41 8% higher- Rotor speed 7% lower ………………….…..lower stress

High Pressure Turbine (HPT)


11/5/2009

New design 2-stage turbine

Same materials as HPT

Based on successful HPT designs- Same design practices

IPT frame based on successful GE90 design

Drives the LPC through a mid-shaft and coupling:- Mid-shaft material and design same as LM6000 - Modified LM2500+ US Navy main drive coupling- Both operating at higher speeds and lower torque

Intermediate Pressure Turbine (IPT)


11/5/2009

Power Turbine

PT Sub-base Assembly (ALF)PT Shaft (ALF)

PT Case(Now fully Assembled))

Aft (Hot End Drive)

New design 5-stage turbine

Same materials as LM6000

Based on successful LPT designs for all GEAE LPT’s

Same pressure ratio, speed and inlet temp as LM6000


11/5/2009

P/N Girth Length9941 110' - 6" 44' - 8"9942 105' - 9" 43' - 2"0014 107' - 8" 44' - 4"0156 117' - 0" 47' - 4"0212 111' - 8" 48' - 2"0238 110' - 8" 44' - 0"

TEI Examples of manufacturing capability

Operating Experience:- Widely used for 40+ years in air industry

- Equivalent flows

- Higher pressures

- Higher temperatures

- Air and multiple gases

- Supplier validated heat exchanger code

Design and Test:- GEAE and GEPS Chief Engineers reviews

- GEPS H machine experience applied

(heat exchangers)

- Component test at GE-Global Research Center

Intercooler – heat exchanger experience


11/5/2009

Redundancy … a key reliability feature

• All reliability key sensors typically include 3 sensors or 2 dual element sensors

• Each signal routed to independent I/O block, eliminating single point failure modes

• Each I/O block communicates to multiple control processors through 2 independent networks

• Each I/O pack is power by two independent power supplies

• Power supply for the control includes a UPS system for backup in loss of AC power

• Mineral lube oil system includes redundant AC pumps and a backup DC pump

• Intercooler system includes dual 100% circulation pumps.

• Turbine hydraulic systems include redundant AC pumps and a backup DC pump

• Turbine enclosure ventilation includes redundant fans

• Generator ventilation includes redundant fans

• Power turbine load cage cooling includes a redundant blower.


11/5/2009

GE committed to providing the best product at the lowest risk

Robust NPI process

Operating conditions within current experience levels

Design based on existing gas turbine components and modules

Full scale validation testing

Fleet leader program

Reliability roadmap


11/5/2009

Comprehensive full scale validation tests

Combustor rig

Instrumented core engine

Production core engine

Instrumented power plant (FETT)

Production gas turbine generator set


11/5/2009

GE’s altitude test facility … ideal for matching LMS100 operating conditions

Provided required flow rate, at depressed inlet temperatures and elevated inlet pressures to simulate the LMS100 intercooler discharge conditions.

460 lbs/sec airflow

35-38 psia inlet pressure

~110°F inlet temperature


11/5/2009

Core engine test vehicle heavily instrumented…

• Dual fuel combustion system … liquid (Jet A / Diesel) or natural gas with water injection capability

• Configured with both forward and aft instrumentation slip rings.

Core Engine Cross-Section

• Slave front frame and aft frame

from flight engines

• Over 1500 pieces of instrumentation … system or component pressures, temperatures, and mechanical strains (stresses).


11/5/2009

Successful core engine test

• Great results …66+ hours / 74 starts

• 2 engine cell installations and test … June & November 2004

• Collected significant data:

– 500 transient data recordings

– 800 steady-state recordings

• Achieved 100% start reliability

• Rotor thrust balance verified

• Cleared all rotating hardware for aeromechanics

• Demonstrated core engine mechanical integrity


11/5/2009

LMS100 full load test stand

Evap cooling towers

Test facility capacity

120MW load banks

First-Engine-to-Test (FETT)

instrumentation data trailer

Modified 6FA inlet system Intercooler/

Heat exchangerAuxiliary

skid

Intercooler water

pump skid

VBV silencer stack

Variable bleed valves (VBV)


11/5/2009

Full load test objective … validate simple cycle power plant design

Full load test of the gas turbine generator set

Fully operational intercooler system

Complete package validation

Mark VI control system validation

Auxiliary skid “ring-out”

Full sensor suite across GT and package

Over 2500 sensors installed

Full range of operation covered


11/5/2009

Significant accomplishments

• Operated at max power conditions …110MW’s meeting requirements

• Demonstrated ability to meet heat rate

requirements

• Demonstrated 10 minute start ability

• Demonstrated load following ability

• Demonstrate ability to meet emissions requirements

• Conducted aeromechanic evaluations

• Evaluated rotor system vibration

• Conducted operability studies

• Conducted transient studies

• Validated all subsystems; MLO, start, fuel,water injection, gas and liquid fuel

• Demonstrated intercooler loop Variable Bleed Valve (VBV) system

• Demonstrated start capability on gas and liquid fuel

• Demonstrated gas fuel operation with water injection

Total test time: 121 hrs

Gas 110 hrs

Liq 11 hrs

Total # starts: 69


11/5/2009

10-minute starts validated

10:48 min to 100 MW

Power

HP rotor speed

PT rotor speed

IP rotor speed

Load bank adjustments caused delays

Not typical for grid operation

Adjusted time < 10 minutes10:48 min to 100 MW

Power

HP rotor speed

PT rotor speed

IP rotor speed

Load bank adjustments caused delays

Not typical for grid operation

Adjusted time < 10 minutes


11/5/2009

0

500

1000

1500

2000

2500

3000

0 200 400 600 800 1000 1200 1400 1600 1800 2000

Time (sec)

Em

iss

ion

s a

t 1

5%

O2

(p

pm

)

0

5000

10000

15000

20000

25000

30000

35000

40000

CO15_M

10XNOx_15_M

WF36corr

Ignition

Warm

Up

Sync

Accel to

power

NOx Water

on

NOx water off

Cool down

Fuel off

Fu

el fl

ow

(p

ph

)

LMS100 PA Startup / Shutdown Emissions Profile

* NOx values shown are the actual values multiplied by 10, for purposes of plotting.


11/5/2009

• Common 50/60 Hz generator………………….…………..+ fleet reliability

• Common GT and Package – both intercooler system…..+ fleet reliability

• No gearbox required for 50 or 60 Hz applications…….…+ performance and cost

• Intercooler options…………………………………………..+ site conditions flexibility

STIG – Steam Injection for power augmentation

Product Type Model

(Fuel Sys) 50Hz 60Hz Dry Wet

LMS100 PA Gas

Dual

Steam

STIG

LMS100 PB DLE

ApplicationIntercooler/

Cooling Tower

Reliability thru commonality – while maintaining flexibility

lms100 gas turbine system - tradekeyimg.tradekey.com/images/uploadedimages/brochures/0/4/1244147...2...

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