Power-GEN Middle East High efficiency gas turbine testing & validation

Transcription

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
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.
3
The industry trend … efficiency & temperature
Advancing efficiency to lower the cost of electricity
Typical Efficiency vs. Temperature Relationship
62
• GE pioneered >1430C 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
2900F
1600C
• 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
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
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
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
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
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
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
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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
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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
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
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
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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
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
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
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
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
Start up tests ongoing
> 3,000 data streams from the assembled test train
20
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
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
HA … experience and validation
driving rapid order growth
>25 Maintaining
units technology50
selected
planned projects
in 60for
momentum
23
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

Power-GEN Middle East High efficiency gas turbine testing & validation

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Power-GEN Middle East High efficiency gas turbine testing &amp; validation

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