Power-GEN Middle East High efficiency gas turbine testing & validation
Power-GEN Middle East High efficiency gas turbine testing & validation Marcus H. Scholz Abu Dhabi, UAE | 12-14, October 2014 © 2014, General Electric Company. Proprietary information. All rights reserved. GE Power & Water © 2014, General Electric Company. GE Proprietary Information - The information contained in this document is General Electric Company (GE) proprietary information. It is the property of GE and shall not be used, disclosed to others or reproduced without the express written consent of GE, including, but without limitation, in the creation, manufacture, development, or derivation of any repairs, modifications, spare parts, or configuration changes or to obtain government or regulatory approval to do so, if consent is given for reproduction in whole or in part, this notice and the notice set forth on each page of this document shall appear in any such reproduction in whole or in part. The information contained in this document may also be controlled by the US export control laws. Unauthorized export or reexport is prohibited. All relative statements are with respect to GE technology unless otherwise noted. 2 © 2014, General Electric Company. Proprietary information. All rights reserved. Agenda • Gas turbine industry trends • Systematic approach to validation past & present - • 7F.05 gas turbine validation • 9HA gas turbine unit #1 testing progress • 9HA gas turbine unit #2 site progress • Summary * Trademark of General Electric Company. © 2014, General Electric Company. Proprietary information. All rights reserved. 3 The industry trend … efficiency & temperature Advancing efficiency to lower the cost of electricity Typical Efficiency vs. Temperature Relationship 62 • GE pioneered >1430C a decade ago with H-class technology 60 CC efficiency • H-class … >1430⁰C needed for >60% efficiency 58 56 • Six H-class units in operation >200,000 operating hours 54 • Last decade … steam cooling used 52 2000 2300 2600 1100 1260 1430 E-Class F-Class H-Class 2900F 1600C • Today … offering largest H-class gas turbine with air cooling (HA gas turbine) Gas turbine firing temperature Technology advances govern firing temperature … to lower fuel costs 4 © 2014, General Electric Company. Proprietary information. All rights reserved. Experience matters … 4,500 units 189 MM hours 2.6 MM starts Global installed base Fired hours Gas turbine installed base ~1,000 GW Source: McCoy Power Reports, estimate based on reported orders. GE Fleet All Others 97.8 97.4 +0.4 Availability 92.6 91.1 +1.5 Start Reliability 98.0 97.6 +0.4 Reliability 156 Fired starts Source: 120 ORAP®. All rights to underlying data reserved: SPS®. Modified by GE. Rolling 12-month data Apr'13 - Mar'14. GE’s leading experience feeds our technology advancements 5 © 2014, General Electric Company. Proprietary information. All rights reserved. GE’s product portfolio Reliable, flexible, efficient GE GT-9HA .02 .01 GE GT-9F .05 .03 GE GT-9E .03 397 MW 299 MW 265 MW 130 MW .02 .05 .04 GE GT-7E .03 GE GT-6F .03 .01 GE GT-6B .03 World’s Largest 61%+ Net CC Efficiency 330 MW 275 MW GE GT-7HA .01 GE GT-7F 470 MW 227 MW 187 MW 90 MW 79 MW 51 MW 43 MW 50Hz gas turbines 60Hz gas turbines Geared for 50Hz or 60Hz 6 © 2014, General Electric Company. Proprietary information. All rights reserved. A continuous progression of performance … which builds upon experience GE industry firsts • Invented F-class, 1986 (60Hz) • Pioneered H-class, 2003 (50Hz) • First single-digit DLN combustor • First to 1,000 units (>150 MW) • First in reliability & availability Today’s H-class • Air cooled • Superior flexibility • Merge of F and H-class experience • Industry leading output and efficiency Succinct product growth of F-class and H-class heritage 7 © 2014, General Electric Company. Proprietary information. All rights reserved. Systematic approach to validation • Rigorous validation approach….building on Aviation model • Address high technical challenges early…understand and mitigate • Systematic “stair-step” building block • Increasing commonality between platforms System Sub-System 2012 Component Science 2003 2001 2004 A tiered process to build on reliability at final test 8 © 2014, General Electric Company. Proprietary information. All rights reserved. Combustion lab since 2001 DLN 2.6+ lab tested • 210 combustion tests per year • Validating: Emissions <25 ppm NOx (9HA) Fuel range (MWI) ±10% (9HA) Turndown 30% base load (9HA) Combustion dynamics Durability ... and field validated • 67 operating 9 F-class gas turbine units • >1,300,000 fired hours Subsystem level validation with proven fuel flexibility 9 © 2014, General Electric Company. Proprietary information. All rights reserved. Advanced compressor test in 2011 7F.05 compressor 2011 • Tested in June 2011 • Fully mapped compressor • 90% – 110% speed range 9HA compressor 2013 • Two fully assembled rotors • Fully instrumented • Full load in 2014 Subsystem validation of capability with growth potential 10 © 2014, General Electric Company. Proprietary information. All rights reserved. GE’s Aero Engine testing - “a decade of validation” Jet engine test cell GE off grid test stand Peebles, Ohio Greenville South Carolina • • • • • Speed range… 1 RPM to >3900 RPM Load range... 1 MW to 110% MW Transients… Instrumentation … > 3000 sensors Data acquisition… terabites World-class validation … inspired by aviation testing 11 © 2014, General Electric Company. Proprietary information. All rights reserved. Thorough validation prior to first fire in the field Unique 50 Hz and 60 Hz full load, variable frequency facility Validation schedule 7F.05 2012 • 9HA 2014 • 7HA 2015 Corrected flow Example … 7F.05 results Pressure ratio • Unique facility validates full load and beyond • Variable speed, load and pressure • Validates extreme transient behavior Compressor + GT validation 7F.03 fleet data (600+ units) System level validation on a lifecycle basis 12 © 2014, General Electric Company. Proprietary information. All rights reserved. 7F.05 gas turbine acceptance and commercial operation validated in 2012 in GE’s test stand facility Commercial acceptance enabled by GE’s test facility Timeline • Announced 2008 • Test Stand validation 2012 • COD 2014 Units on order 53 + tech selections 71 6 Units in service in Saudi Arabia Comparison basis: previous 7F versions Clear customer choice for reliable, cost effective power generation 13 © 2014, General Electric Company. Proprietary information. All rights reserved. Off-grid testing benefits No grid restrictions… no “speed limit” Replicates all ambient extremes and operational transients Allows to derive full compressor operating map Can explore repeated surge or stall events Validates gas turbine prior to first fire Exploring growth potential Test bed capability exceeds any site operating envelope 14 © 2014, General Electric Company. Proprietary information. All rights reserved. Test stand validation for grid code compliance Off-nominal frequency operation • Successfully tested steady state operation between 90 -108% speed (54 – 64.8 Hz) • Successfully performed 46 speed sweeps between 90-110% speed 7F.05 Loaded SS Off-speed Points Load control validation • Successfully tested grid step response between -1% and +1% grid change • Load changes >25% load /min. +1% Frequency Shift at 140MW 61.2 Hz 57.5 Hz Mass flow Typical grid frequency requirements Validation beyond global grid code requirements 15 © 2014, General Electric Company. Proprietary information. All rights reserved. HA gas turbine evolution A systematic progression of proven technology 9H 9F.05 7F.05 2003 2005 2012 4-stage VGV 4-stage turbine DLN 2.6+ 14-stage compressor Field-replaceable blades 3-stage VGV Advanced HGP 9HA 2014 Note: Year denotes first operation A decade of technology advances and lessons learned 16 © 2014, General Electric Company. Proprietary information. All rights reserved. 9HA power turbine experience Performance and enhancements • Double wall casing for tighter clearances (Hsystem) • Advanced Gas Path (AGP) experience from 7F.04 and 7F.05 gas turbines 51 in operation • 4-stage technology scaled from 9H gas turbine • Aero engine sealing technology Hot gas path materials • • • • • Single crystal technology Reduced oxidation and creep Improved low-cycle fatigue Air-cooled hardware for flexibility benefits “F” & “H” - turbine heritage Hot gas path material selection supports longest rotor life 17 © 2014, General Electric Company. Proprietary information. All rights reserved. First 9HA gas turbine assembled and shipped Jan. 2014 Turbine features: • Superalloy rotor materials • F-class materials • Advanced cooling and sealing Compressor features: • 14-stage, 3D aero configuration • Pressure ratio 21:1 • 3 stages VSV Second generation “air cooled” H-class gas turbine … 61% + CC efficiency 18 © 2014, General Electric Company. Proprietary information. All rights reserved. 9HA gas turbine full load testing underway October 2014 Results more relevant than 8,000 hour field operation Capabilities • Variable frequency & load testing • Gas fuel and liquid fuel options • Load shedding and grid response characterization • Pyrometry and real time IR cameras 9HA gas turbine #1 is fully dedicated to the test program 19 © 2014, General Electric Company. Proprietary information. All rights reserved. Start up tests ongoing > 3,000 data streams from the assembled test train 20 © 2014, General Electric Company. Proprietary information. All rights reserved. 9HA instrumentation and number of sensors includes > 1000 thermal crystals Hot Gas Path • >200 rotating • >800 structures Combustion system • >350 Stator vanes & blades • >120 rotating • >400 structures Complete test train contains > 500 rotating and > 3000 static sensors 21 © 2014, General Electric Company. Proprietary information. All rights reserved. 9HA gas turbine 2 site construction EdF Bouchain: Site works ongoing Main control and power train behind ST condenser in place On schedule for commissioning end of 2015 22 © 2014, General Electric Company. Proprietary information. All rights reserved. HA … experience and validation driving rapid order growth >25 Maintaining units technology50 selected planned projects in 60for momentum 23 © 2014, General Electric Company. Proprietary information. All rights reserved. Summary Component and subsystem tests build the foundation for the final systems validation 9HA gas turbine 1 installed & rotating – firing imminent Large 600MW Generator passed running test successfully Industry leading testing & validation capability acknowledged through early orders pipeline for 7F.05 and HA technology. Commercial success is supported through insurance & financing institutions HA technology – a new standard in technology validation 24 © 2014, General Electric Company. 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