BHEL GT Recent Developments

BHEL Heavy Duty Gas Turbines - Re Rec cen entt Dev Devel elo opm pmen ents ts

Re c e n t d e ve lo p m e n t s  

• Up-rated Models

• New Models • Large Advance class Gas Turbines •  Areas of Improved design desi gn •  Advanced materials and coatings • IGCC

Re c e n t d e ve lo p m e n t s  

• Up-rated Models

• New Models • Large Advance class Gas Turbines •  Areas of Improved design desi gn •  Advanced materials and coatings • IGCC

U p r a t e d  V e r s i o n s  

• Fr-6B • Fr-9E • Fr-6FAe+

PG6581B PG9171E PG6111FA

N e w M o d els  

• Fr-6C • Fr-9FA • Fr-9FB

PG6591C PG9351FA PG9371FB

P G 6 5 8 1 B – I m p r o v e m e n t s  

• • • • • • • •

Increased Shaft speed – 5163 Increased firing temperature – 1140 deg C Improved turbine sealing Reduced compressor leakage – Brush seal 13th stage air for cooling Stage 2 Nozzle Improved N#1,B#1 High performance exhaust diffuser Split Accessory Base

PG6561 PG6581 Output, kw

39620

42100

SC Heat Rate, kcal/kwhr 2700

2680

Exhaust Flow, tons/hr

519

530

Exhaust Temp, deg C

532

548

ISO,Base,Gas

P G 6 5 8 1 B – S t a g e 1 N o z z l e  

• Enhanced cooling of •

platforms and aerofoils. Improved leakage control  – chordal hinge and additional spline seal.

P G 6 5 8 1 B – S t a g e 1 B u c k e t  

• New Bucket profile • Optimized cooling •

configuration Existing GTD111DS material and coating technology

P G 6 5 8 1 B – S t a g e 1 S h r o u d  

• Redesigned internal • •

cooling system Improved leakage control HR 120 material Circumferential braided seal location

Impingement Sleeve

P G 6 5 8 1 B – S t a g e 2 N o z z l e  

• Optimization of cooling •

( 13 stage bleed air). Existing material and coating technology.

P G 6 5 8 1 B – S t a g e 2 B u c k e t  

• Enhanced cooling of airfoil. • Contoured tip shroud for •

creep life improvement. Nickel Base alloy material.

P G 6 5 8 1 B – E x h a u s t D i f f u s e r  

• Improved performance • Minimum design changes • Enlarged exhaust plenum •

bottom and extensions Enlarged internal diffuser profile ring extension

P G 9 1 7 1 E – L a t e s t E v o l u t i o n  

PG9171E

PG9171E+

Output, kw

123400

126100

Heat Rate, kcal/kwhr

2545

2545

Exhaust Temp, deg C

544

543

Exhaust Flow, tons/hr 1502

1505

P G 9 1 7 1 E – L a t e s t i m p r o v e m e n t   • Turbine Sealing • •

improvement Improved First stage shroud One piece design, HR120 material with cloth spline seal

P G 9 1 7 1 E – L a t e s t I m p r o v e m e n t s   • Improved 2nd Stage • •

Shroud Sealing Non pressurized diaphragm Brush Seal

P G 9 1 7 1 E – L a t e s t I m p r o v e m e n t s   • High performance exhaust diffuser.

P G 6 1 1 1 F A – K e y f e a t u r e s   • Increased Firing • • •

temperature Increased air flow Higher pressure ratio Robust rotor design, No startup dwell time

P G 6 1 1 1 F A - P e r f o r m a n c e  

• • • • • • • •

Quantum jump in firing temperatures Higher efficiencies ( Simple & CC ) More power from single units Superior metallurgy Novel Cooling techniques Novel sealing methods Improved emissions Better topping machines for a combined cycle

•

E-

Firing temperature C

1124

Exhaust temperature C

F-

H-

1400

~ 1450

543

610

NA

Combined cycle eff. %

52

58

60

Power ( GT) MW ( Fr-9)

126.1

279

~300

HGP Cooling

 Air

 Air

Blade Casting

DS

SC

Simple cycle eff %

33.7

38

Nox ppm

42/25

25/15

Steam SC NA 25/15

•

8000

   )   r    h      W    k    /    U    T 7000    B    (   e    t   a    R    t   a   e    H 6000

6B 7EA

“E” Technology

9E

6FA

“F” Technology

7FA 9FA

0

100

200

300

400

Rating MW

500

600

700

800

Gas Turbines : New Models

PG6591C

• Flow back of F Technology into mid range Gas turbines • Evolutionary design based on proven technologies − Built on 6B’ s track record − Flow down of F technology

 Advanced class GAS TURBINE in the 40 MW range.

Comparision of 6B vs 6C

− 18 Stage compressor − IGV  − 10 combustion chambers − Std/DLN1 Combustor − 3 Stage turbine

− 12 Stage compressor − IGV and 2 variable stator blades − 6 combustion chambers − DLN 2 Combustor − 3 Stage turbine

030

Comparision of 6B vs 6C

ISO Rating

MW

41.7

45.4

Heat Rate

Kcal/kwhr

2695

2348

kg/sec

143

122

12.2

19.6

 Air Flow Pressure ratio Firing Temp.

c

1140

1327

Exhaust Temp.

c

547

581

5163

7100

GT Speed

rpm

030

Comparision of 6B vs 6C – Key Benefits

• Improved operability − Fast and reliable start − Nox turn down to less than 50 % • Improved performance − 5% improvement in efficiency over 6B − 7.5 % improvement in output over 6B − 3 stages of guide vanes for higher part load •

efficiency − Low NOx emissions 15 ppm NOx and 9 ppm CO Layout −  Axial exhaust − F class modular arrangement of skids

 All compressor blades are field replaceable without rotor removal

030

Gas Turbines : New Models PG9351FA Description

Fr 9FA

ISO Rating

255600 MW

Heat Rate

2332 Kcal/KWH

Simple Cycle Efficiency

36.9 %

Combined Cycle Efficiency

up to 56.2%

 Air Flo w

647 kg s /sec

Firing Temp.

1327 c

Exhaust Temp.

602 c

Pr. Ratio

16.5

RPM

3000

Overall Wt.(Turbine Base

280 T

Overall Dimensions( Turbine )

11.0 x 5.0m x 5.0m

Rotor Wt/Length

77T / 10.0 m

030

Gas Turbines : New Models PG9371FB Fr-9FB : PG9371FB

Gas Turbines : New Models PG9371FB Fr-9FB : PG9371FB

030

Sealing Technology Better sealing technology through use of  − Honey comb seals.

− Brush seals. − Cloth seals. −  Abraidable coating seals.

The Labyrinth Seal Stationary Part

Rotating Part

Sealing Locations

At present in F machines Further advancement

Honey Comb Seal

Honey comb seals inserted between labyrinth seal teeth Honey comb seal material softer than bucket and shroud Cutter tooth on bucket tip 0.6 % improvement in output and heat rate

Brush Seal

Brush seal on Nozzle

Typical Brush Seal element

Shroud Cloth Seals

 – Both radial & axial sealing.  – Flexible,allows shroud block misalignment.  – Performance improvement of up to 0.7 % in output and 0.5 % in heat rate.

 Abraidable coating on shroud 40 mil thick coating on the 1st stage shroud block. Bucket tips rub into the coating and form gas path. Misalignment of components automatically taken care of. Reduced air leakage leads to 0.4 % improvement in output & heat rate.

Cooling Technology

Better cooling technique. Reduced cooling air requirement due to better materials. More air available for power generation. Serpentine cooling path in 1st stage buckets. Radial cooling holes in 2nd stage buckets. Film cooling in Nozzles. Hollow Nozzles. Impingement cooling of Transition piece.

Cooling air circuit

Last stage wheel with cooling air extraction

Internal cooling air circuit

Cooling Passages

First stage bucket cooling passages

Impingement cooling of Transition piece Transition piece in two pieces. Inner transition piece is surrounded by slotted sleeve.  Air jets impinge on the inner transition piece

Transition piece

Improved material Hayes HR120 ( Ni-Cr alloy) replaces 310SS Single piece design Reduced cooling air requirement

Equiaxed Vs DS • Directionally solidified 1st stage buckets for better creep rupture strength and fatigue life

Firing temperature trend and Bucket material capability

IGCC Fuels Bitum. Coal

Gassification

Lignite

Gasifier

Orimulsion

HX

Cleanup Products

Residual oils Pet coke Bio Mass Wastes

Oxyg.

Combined

System

Cycle Hydrogen

• 2 Stage combustion

Ammonia

• Partial in Gassifier

Methnol

• Complete in GT

Sulfur

Electricity

IGCC Coal Gas 16% Nat Gas 2%

NG Exhaust 102% C.G Exhaust 116%

 Air 100%

Low LCV Gas

Flat rated region

Output • 20% Extra Output Nat. Gas Typically • 14 % extra flow at same firing Temp makes 28% more power

15 C

 Ambient Temp