L04.0 - 20200_a_A_ppt_04 - GAS TURBINES_56s.pdf

gaz pour turbine

1. EP 20200_a_A_ppt_04 – GAS TURBINES (GT)
GAS TURBINES (GT)

2. ©

2010
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IFP Training

EP 20200_a_A_ppt_04 – GAS TURBINES (GT) 2
COURSE OUTLINE
1.GENERAL DESCRIPTION
2.TYPES OF GAS TURBINE
•Single-shaft of Split-shaft design
•Heavy Duty or Aeroderivative Gas Turbine
3.TYPES OF CYCLE
4.POWER RATING
5.MARKET AND (HEAT) EFFICIENCIES
6.FUELS AND COMBUSTION
7.GAS TURBINE OPERATION
8.GAS TURBINE MAINTENANCE

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2010
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IFP Training

EP 20200_a_A_ppt_04 – GAS TURBINES (GT) 3
GENERAL DESCRIPTION – THM 1304 (MAN-TURBO) – 8 MW
Air intake
casing
Air
Compressor
Air supply
Fuel
Supply
Combustion
Chamber
HP
Turbine
LP
Turbine
Exhaust
Breech
Piece
Driven
Machine
Coupling

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IFP Training

EP 20200_a_A_ppt_04 – GAS TURBINES (GT) 4
GENERAL DESCRIPTION

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IFP Training

EP 20200_a_A_ppt_04 – GAS TURBINES (GT) 5
GENERAL DESCRIPTION
Fuel gas and air flows through an annular chamber

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IFP Training

EP 20200_a_A_ppt_04 – GAS TURBINES (GT) 6
GENERAL DESCRIPTION

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IFP Training

EP 20200_a_A_ppt_04 – GAS TURBINES (GT) 7
GENERAL DESCRIPTION

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IFP Training

EP 20200_a_A_ppt_04 – GAS TURBINES (GT) 8
SMALL POWER EMERGENCY GENERATOR (≈ 1 MW)
GENERAL DESCRIPTION – SMALL GAS TURBINE

9. ©

2010
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IFP Training

EP 20200_a_A_ppt_04 – GAS TURBINES (GT) 9
COURSE OUTLINE
1.GENERAL DESCRIPTION
2.TYPES OF GAS TURBINE
•Single-shaft of Split-shaft design
•Heavy Duty or Aeroderivative Gas Turbine
3.TYPES OF CYCLE
4.POWER RATING
5.MARKET AND (HEAT) EFFICIENCIES
6.FUELS AND COMBUSTION
7.GAS TURBINE OPERATION
8.GAS TURBINE MAINTENANCE

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2010
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IFP Training

EP 20200_a_A_ppt_04 – GAS TURBINES (GT) 10
TYPES OF GT – SINGLE-SHAFT OR SPLIT-SHAFT DESIGN
SINGLE-SHAFT: all rotating components are on the SAME SHAFT and rotate
at same speed
•A very narrow speed range over which it can operate due to:
−Minimum speed set by the surge limit of the air compressor
−Maximum power set by the maximum allowable temperature at the inlet of the power
turbine section.
•Used in constant-speed, variable-load applications, such as powering an electric
generator
•Another disadvantage of single-shaft turbines is that the starting power
requirements may be large.
•To keep this starting requirement as low as possible, it may be necessary to
unload the driven equipment during start-up.

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IFP Training

EP 20200_a_A_ppt_04 – GAS TURBINES (GT) 11
TYPES OF GT – SINGLE-SHAFT OR SPLIT-SHAFT DESIGN
SPLIT-SHAFT: some of the power turbine wheels are on same shaft as air
compressor while some are on same shaft as driven equipment
•Only power output limitation is the maximum allowable temperature at the inlet
of the turbine section. In actual practice a torque limit, increased exhaust
temperature, loss of turbine efficiency and (or) a lubrication problem on the
driven equipment usually preclude operating at very low power turbine speeds.
•Wide speed range or a high starting torque. The gas compressor is able to run at
its most efficient speed while the power turbine speed varies with the driven
equipment.
•The split shaft design allows a small starting system since only the gas compressor
shaft is accelerated during the start cycle.
•Compressors, pumps, and various mechanical drive systems make very good
applications for a split shaft designs.

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IFP Training

EP 20200_a_A_ppt_04 – GAS TURBINES (GT) 12
TYPES OF GT – SINGLE-SHAFT TUBINE
SIEMENS V 64 GENERATING SET – AXIAL FLOW EXHAUST – DRIVEN EQUIPMENT AT COMPRESSOR SIDE

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IFP Training

EP 20200_a_A_ppt_04 – GAS TURBINES (GT) 13
TYPES OF GT – TWO-SHAFT TUBINE
4 MW TURBINE – TWO-SHAFT DESING – RATHER DEDICATED TO MECHANICAL DRIVE

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IFP Training

EP 20200_a_A_ppt_04 – GAS TURBINES (GT) 14
TYPES OF GT – THREE-SHAFT TUBINE
Front
Compressor
Rear
Compressor
Combustor
Rear Compressor
Drive Turbine
Front Compressor
Drive Turbine
Power
Turbine
Exhaust
Chamber
Power
Shaft

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IFP Training

EP 20200_a_A_ppt_04 – GAS TURBINES (GT) 15
COURSE OUTLINE
1.GENERAL DESCRIPTION
2.TYPES OF GAS TURBINE
•Single-shaft of Split-shaft design
•Heavy Duty or Aeroderivative Gas Turbine
3.TYPES OF CYCLE
4.POWER RATING
5.MARKET AND (HEAT) EFFICIENCIES
6.FUELS AND COMBUSTION
7.GAS TURBINE OPERATION
8.GAS TURBINE MAINTENANCE

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IFP Training

EP 20200_a_A_ppt_04 – GAS TURBINES (GT) 16
TYPES OF GT – HEAVY DUTY OR AERODERIVATIVE
First widely used as an aircraft power plant. However, as they became more
efficient and durable, they were adapted to the industrial market place.

Over the years the gas turbine has evolved into two basic types for high
power stationary applications: the industrial or heavy-duty design and the
aircraft derivative design.

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IFP Training

EP 20200_a_A_ppt_04 – GAS TURBINES (GT) 17
TYPES OF GT – HEAVY DUTY
Design of the heavy-duty type has been developed to satisfy normal
industrial process-plant requirements, without any space and weight
limitation.
It is designed exclusively for STATIONARY use.
Where high power output is required, 26 000 kW (35 000 hp) and above, the
heavy duty industrial gas turbine is normally specified.
ADVANTAGES are:
•less frequent maintenance (overhaul every 30 000 - 36 000 hours; stopping: about
1 month !!!!), due to smooth operating conditions (pressure ratio 6 to 10;
maximum power gas temperature: about 1 100°C),
•can burn a wide variety of fuels,
•available in large horse power sizes.

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IFP Training

EP 20200_a_A_ppt_04 – GAS TURBINES (GT) 18
TYPES OF GT – HEAVY DUTY
LARGE POWERED GE 107 F DEIGNE FOR COMBINED CYCLE

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IFP Training

EP 20200_a_A_ppt_04 – GAS TURBINES (GT) 19
TYPES OF GT – AERODERIVATIVE
Sophisticated AIRCRAFT technology and associated research, laboratory facilities,
quality control methods, test and maintenance facilities… can be directed to
industrial purposes
HIGHER EFFICIENCY than heavy-duty type units due to severe operating conditions
(pressure ratio above 30; gas power temperature above 1 100°C),
Quick overhaul capability (overhaul every 10 000 hours; stopping about 24 hours !!!),
LIGHTER and more COMPACT. An asset where weight limitations are important such
as offshore installations.
For large power ratings, more efficient than even the heavy-duty regenerative gas
turbine.
Inherently, the aircraft-derivative gas turbine is of either the two- or three-shaft
configuration, depending on the jet engine design.
The power turbine and the gas generator (the jet engine) are separate entities, with
no mechanical linkage. This separation also applies to the auxiliary systems.

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IFP Training

EP 20200_a_A_ppt_04 – GAS TURBINES (GT) 20
TYPES OF GT – AERODERIVATIVE
RB 211 – FOR GAS POWER GENERATOR

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IFP Training

EP 20200_a_A_ppt_04 – GAS TURBINES (GT) 21
TYPES OF GT – AERODERIVATIVE
AIRCRAFT ROLLS ROYCE R 211 ENGINE
TWO-SPEED COMPRESSORS & TURBINES
FAN: 80% MASS FLOW AND THRUST
RB 211 GAS GENERATOR
FOR INDUSTRIAL APPLICATION
FAN NO MORE USED

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2010
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IFP Training

EP 20200_a_A_ppt_04 – GAS TURBINES (GT) 22
COURSE OUTLINE
1.GENERAL DESCRIPTION
2.TYPES OF GAS TURBINE
•Single-shaft of Split-shaft design
•Heavy Duty or Aeroderivative Gas Turbine
3.TYPES OF CYCLE
4.POWER RATING
5.MARKET AND (HEAT) EFFICIENCIES
6.FUELS AND COMBUSTION
7.GAS TURBINE OPERATION
8.GAS TURBINE MAINTENANCE

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2010
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IFP Training

EP 20200_a_A_ppt_04 – GAS TURBINES (GT) 23
TYPES OF CYCLE – OVERVIEW
 Single cycle – Brayton cycle
 Regenerative cycle
 Combined cycle
 Cogeneration application

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IFP Training

EP 20200_a_A_ppt_04 – GAS TURBINES (GT) 24
TYPES OF CYCLE – SINGLE CYCLE
Two-shaft design turbine with open cycle to atmosphere
Requirement to improve efficiency

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IFP Training

EP 20200_a_A_ppt_04 – GAS TURBINES (GT) 25
TYPE OF CYCLE – REGENERATIVE CYCLE
Man turbo THM 1304 with regenerative cycle

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2010
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IFP Training

EP 20200_a_A_ppt_04 – GAS TURBINES (GT) 26
TYPE OF CYCLE – COMBINED CYCLE
Combined cycle performance depends on:
 Turbine inlet temperature
 Pessure ratio

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IFP Training

EP 20200_a_A_ppt_04 – GAS TURBINES (GT) 27
TYPE OF CYCLE – COGENERATION APPLICATIONS
GE Frame 5 generating set 14/18 MW electrical production
Steam production:

•40 t/h steam flow rate without post combustion
•70 t/h, 40 bars steam with post combustion
(post combustion is done with residual oxygen of exhaust gas in
boiler)

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IFP Training

EP 20200_a_A_ppt_04 – GAS TURBINES (GT) 28
TYPE OF CYCLE – COGENERATION APPLICATIONS
1,400 MW POWER PLANT – FOUR 250 MW HEAVY DUTY GAS TURBINES & SIX 140 STEAM TURBINES

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IFP Training

EP 20200_a_A_ppt_04 – GAS TURBINES (GT) 29
TYPE OF CYCLE – COGENERATION APPLICATIONS
INTEGRATED GASIFICATION COMBINED CYCLE (IGCC) PLANT – HEAVY DUTY GAS TURBINES

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IFP Training

EP 20200_a_A_ppt_04 – GAS TURBINES (GT) 30
COURSE OUTLINE
1.GENERAL DESCRIPTION
2.TYPES OF GAS TURBINE
•Single-shaft of Split-shaft design
•Heavy Duty or Aeroderivative Gas Turbine
3.TYPES OF CYCLE
4.POWER RATING
5.MARKET AND (HEAT) EFFICIENCIES
6.FUELS AND COMBUSTION
7.GAS TURBINE OPERATION
8.GAS TURBINE MAINTENANCE

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IFP Training

EP 20200_a_A_ppt_04 – GAS TURBINES (GT) 31
POWER RATING – FACTORS CONSIFDERED FOR DESIGN
Maximum ambient air temperature,
Altitude above sea level,
Air inlet FRICTION losses and exhaust flue gas FRICTION losses,
Turbine fouling and turbine wear,
Losses into the gear box, when a compressor is driven by a gas turbine.

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IFP Training

EP 20200_a_A_ppt_04 – GAS TURBINES (GT) 32
PRELIMINARY ESTIMATION OF POWER DELIVERED ON SITE
POWER RATING – ESTIMATION OF POWER DELIVERED ON SITE

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IFP Training

EP 20200_a_A_ppt_04 – GAS TURBINES (GT) 33
Atmosphere Delta P (mm W.S.) Letter
Normal 100 A
Dirty 125 B
Desert or
offshore
150 C
TYPICAL ADMISSION FRICTION LOSSES
Equipment Delta P (mm W.S.) Letter
Stack with
silencer
100 D
Recovery boiler 250 E
Boiler with
partial
combustion
350 F
Boiler with total
combustion
500 G
TYPICAL EXHAUST FRICTION LOSSES
POWER RATING – ESTIMATION OF POWER DELIVERED ON SITE

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IFP Training

EP 20200_a_A_ppt_04 – GAS TURBINES (GT) 34
COMPRESSOR DRIVER GE 7EA GE 6B
ISO power in MW 84.9 39.9
Correction factors:
Temperature (29 °C)
Elevation (0 m)
DP admission / exhaust
Gear box
Aging
Compressor fouling

0.905
1
0.975
1
0.96
0.98

0.90
1
0.975
0.98
0.96
0.98
On site power 70.48 32.28
Helper 8.7 8.7
On site available power 79.18 40.98
ESTIMATION OF
ON SITE AVAILABLE POWER
Compressor power (MW) 21.36
Correction factors:
Temperature (35 °C)
Elevation (0 m)
DP inlet
DP outlet
Gear box
Aging + fouling

0.85
1
0.985
0.99
0.98
0.94
Required ISO power 27.97
Selected turbine NP MS5002C
ISO power of selected turbine 28.34
ESTIMATION OF
REQUIRED ISO POWER
POWER RATING – EXAMPLES

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IFP Training

EP 20200_a_A_ppt_04 – GAS TURBINES (GT) 35
COURSE OUTLINE
1.GENERAL DESCRIPTION
2.TYPES OF GAS TURBINE
•Single-shaft of Split-shaft design
•Heavy Duty or Aeroderivative Gas Turbine
3.TYPES OF CYCLE
4.POWER RATING
5.MARKET AND (HEAT) EFFICIENCIES
6.FUELS AND COMBUSTION
7.GAS TURBINE OPERATION
8.GAS TURBINE MAINTENANCE

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IFP Training

EP 20200_a_A_ppt_04 – GAS TURBINES (GT) 36
MARKET AND (HEAT) EFFICIENCIES – HEAVY-DUTY

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IFP Training

EP 20200_a_A_ppt_04 – GAS TURBINES (GT) 37
MARKET AND (HEAT) EFFICIENCIES – AERODERIVATIVE

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IFP Training

EP 20200_a_A_ppt_04 – GAS TURBINES (GT) 38
COURSE OUTLINE
1.GENERAL DESCRIPTION
2.TYPES OF GAS TURBINE
•Single-shaft of Split-shaft design
•Heavy Duty or Aeroderivative Gas Turbine
3.TYPES OF CYCLE
4.POWER RATING
5.MARKET AND (HEAT) EFFICIENCIES
6.FUELS AND COMBUSTION
7.GAS TURBINE OPERATION
8.GAS TURBINE MAINTENANCE

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IFP Training

EP 20200_a_A_ppt_04 – GAS TURBINES (GT) 39
FUEL & COMBUSTION – OVERVIEW
COMPOSITION of the gas (normal, alternate, or start-up) to be supplied
In normal operation, LHV should not change by more than +/- 10%
NO LIQUIDS at the gas turbine fuel nozzle (separators or knockout drums)
FG temperature at fuel nozzle pressure must be above the HC dew temperature of
the fuel gas at this pressure (generally +15°C to +20°C)
Contaminants: Rust, water, Naphtalenes  Filtration down to 5-10 ppm
Corrosive agents: H2S, RSH, COS, chlorides Formation of acids, alkali metal
sulphates
NITROGEN OXIDES (NOx) in the flue gas:
•NOx are function of combustion TEMPERATURE and residence times at high temperatures
•NOx emission controlled by INJECTING WATER of boiler-feed quality into the combustors
•Low-NOx combustors ("lean burn" combustors)
•Selective catalytic reduction (SCR): AMMONIA injected into the flue gas upstream of a
catalyst bed. NOx and NH3 form an ammonium salt intermediate that subsequently
decomposes to produce elemental nitrogen and water.

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2010
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IFP Training

EP 20200_a_A_ppt_04 – GAS TURBINES (GT) 40
FUEL & COMBUSTION – TYPES OF COMBUSTION
Different types of combustion
from no load to full load
Types of combustion
according to the load

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IFP Training

EP 20200_a_A_ppt_04 – GAS TURBINES (GT) 41
FUEL & COMBUSTION – ENVIRONMENT PROTECTION
NOx emission controlled by injecting water of boiler-feed quality into the combustors.
Low-NOx combustors "lean burn" combustors as “dry low NOx”
GE Dry low NOx system DNL 1
Fuel nozzles Combustion liner

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IFP Training

EP 20200_a_A_ppt_04 – GAS TURBINES (GT) 42
FUEL & COMBUSTION – ENVIRONMENT PROTECTION
DNL 1 low NOx system performance in NOx and CO emission

43. ©

2010
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IFP Training

EP 20200_a_A_ppt_04 – GAS TURBINES (GT) 43
COURSE OUTLINE
1.GENERAL DESCRIPTION
2.TYPES OF GAS TURBINE
•Single-shaft of Split-shaft design
•Heavy Duty or Aeroderivative Gas Turbine
3.TYPES OF CYCLE
4.POWER RATING
5.MARKET AND (HEAT) EFFICIENCIES
6.FUELS AND COMBUSTION
7.GAS TURBINE OPERATION
8.GAS TURBINE MAINTENANCE

44. ©

2010
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IFP Training

EP 20200_a_A_ppt_04 – GAS TURBINES (GT) 44
GT OPERATION – CONTROL
Control system have to insure following functions:
1. Start up
2. Acceleration rate
3. Speed control
4. Temperature control
5. Shut down
6. Remote control

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IFP Training

EP 20200_a_A_ppt_04 – GAS TURBINES (GT) 45
GT OPERATION – STRAT-UP SEQUENCE
GE generating set star up sequence from stop to no load speed before synchronising
Rotation speed
Inlet Guide
Vanes position
Exhaust temp.
Fuel signal

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2010
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IFP Training

EP 20200_a_A_ppt_04 – GAS TURBINES (GT) 46
GT OPERATION – TEMPERATURE CONTROL
96 CD
Fuel signal
TTRX
TTXM
TTRX
Example of temperature control
Temperature control loop:
•The purpose of the control loop is to control T3
turbine inlet temperature
•Discharge pressure (P2) of compressor and exhaust
temperature (T4) are measured
•Fuel signal is processed from load objective and
preset parameters
Sorting out and
average calculation
To
min
gate
Exhaust
temperature: n
thermocouples
Compressor
discharge
pressure

47. ©

2010
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IFP Training

EP 20200_a_A_ppt_04 – GAS TURBINES (GT) 47
GT OPERATION – LUBE OIL CIRCUIT
Coolers, filters and oil pumps are doubled to insure availability
A third lub oil pump is fitted to insure a safe emergency shut down

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2010
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IFP Training

EP 20200_a_A_ppt_04 – GAS TURBINES (GT) 48
GT OPERATION – FUEL CIRCUIT
Fuel circuit: in most of case, on field application, gas turbine fuel is GAS
Gas have to be gaseous, that mean liquid level in KO drums must be check
carefully
Liquid or excess of flow rate in a gas burner increase a lot the length of the
flame damaging the hot pass and able to destroy the turbine blading
Expansion through the fuel control system must not generate condensate.
Actual fuel gas inlet temperature must protect the turbine against dew
point risk

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IFP Training

EP 20200_a_A_ppt_04 – GAS TURBINES (GT) 49
GT OPERATION – AIR CIRCUIT
Filters efficiencies
and particles sizes
AIR FILTRATION
1- Hard particles larger than 5 microns:
• easy to stop by inertia filters
• dangerous with erosion (compressor)
2- Particles smaller than 10 microns:
• specifically unburnt hydrocarbons generate fouling (compressor)
• can be corrosive
3- Salty particles generally smaller than 5
microns (onshore and offshore locations):
• difficult to filter totally
• introduces chloride and sodium
• a coalescer is necessary

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IFP Training

EP 20200_a_A_ppt_04 – GAS TURBINES (GT) 50
GT OPERATION – AIR CIRCUIT

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IFP Training

EP 20200_a_A_ppt_04 – GAS TURBINES (GT) 51
GT OPERATION – AIR CIRCUIT
Pre-filter as dust louver:
check good operation of extraction blower
Roll o matic:
ΔP switch is generally
automatic, survey end of the roll
Fine final filter is generally pockets assembly on a frame :
quality of filtering depends upon quality of seal tightening
of frames
Coalescer: check humidity recovery
Extraction blower
suction duct
Filter element frame

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2010
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IFP Training

EP 20200_a_A_ppt_04 – GAS TURBINES (GT) 52
GT OPERATION – COMPRESSOR AGEING AND CLEANINING EFFECT
Overhaul effect

53. ©

2010
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IFP Training

EP 20200_a_A_ppt_04 – GAS TURBINES (GT) 53
COURSE OUTLINE
1.GENERAL DESCRIPTION
2.TYPES OF GAS TURBINE
•Single-shaft of Split-shaft design
•Heavy Duty or Aeroderivative Gas Turbine
3.TYPES OF CYCLE
4.POWER RATING
5.MARKET AND (HEAT) EFFICIENCIES
6.FUELS AND COMBUSTION
7.GAS TURBINE OPERATION
8.GAS TURBINE MAINTENANCE

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IFP Training

EP 20200_a_A_ppt_04 – GAS TURBINES (GT) 54
GT MAINTENANCE – INFLUENCE OF OPERATING CONDITIONS

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2010
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IFP Training

EP 20200_a_A_ppt_04 – GAS TURBINES (GT) 55
GT MAINTENANCE – EXAMPLE OF SCHEDULE
Example of maintenance schedule for heavy duty turbine

56. ©

2010
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IFP Training

EP 20200_a_A_ppt_04 – GAS TURBINES (GT) 56
GT MAINTENANCE
compressor Hot gas path
Start motor & auxiliaries