GE's Next 7FA Gas Turbine "Test and Validation"
GE's Next 7FA Gas Turbine "Test and Validation"
GE's Next 7FA Gas Turbine "Test and Validation"
Russ Martin Manager Economic Valuation, Thermal Product Marketing Dave Forry 7FA.05 Platform Manager Stefan Maier 7FA.05 Systems Integration Leader Chris Hansen Program Manager Test Stand Development
2011 General Electric Company. Proprietary. All Rights Reserved. No part of this document may be reproduced, transmitted, stored in a retrieval system nor translated into any human or computer language, in any form or by any means, electronic, mechanical, magnetic, optical, chemical, manual, or otherwise, without the prior written permission of the General Electric Company.
Contents:
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III.
IV.
VI.
Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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To help meet customers growing need to generate more power more efficiently, GE Energy introduces the next evolution of its industryleading 7FA heavy duty gas turbine for the 60 Hz power generation regions. By merging a host of proven technologies leveraged across our product lines, the next evolution of the 7FA gas turbine now offers improvements in output, thermal efficiency, operability and lower life cycle costs, all without compromising the high degree of reliability, availability, and maintainability (RAM), and operational flexibility historically delivered by GEs F-class fleet. Using proven technology from earlier GE models, the latest 7FA gas turbine is coupled with a highly advanced 14-stage axial compressor, providing enhanced performance, operability, and maintainability, in simple and combined cycle configurations.
This experience includes operation in duty cycles ranging from peaking to daily start/stops to base load operation as shown in Figure 2.
4,500
<7FA.02
4,000
7F Fleet Experience
7FA.03 7FB
3,500
10 Hours/Start 50 Hours/Start
3,000
Peaking Duty
Fired Starts
2,500
Cycling Duty
2,000
1,500
1,000
500
0 0 10,000 20,000 30,000 40,000 50,000 60,000 70,000 80,000 90,000 100,000 110,000 120,000 130,000
Fired Hours
Figure 2. 7FA duty cycle for 2009 (base load, cyclic, peak)
To summarize, GE can confidently say its F technology has the: Largest fleet Most operational experience Most reliability1
GE has employed an incremental approach for the evolution of the 7FA.05 gas turbine. Only existing proven technologies are being utilized. Aviation heritage compressor design utilized on heavy duty gas turbines (GE5, GE10, 5002E, 6C) Heavy duty gas turbine compressor mechanical rotor structure Successful DLN2.6 combustor Evolution of the validated 7FA Advanced Hot Gas Path (HGP) turbine section It is important to note that no unproven technologies have been introduced with the 7FA.05 platform.
Compressor
GEs most advanced high efficiency compressor technology, based on prior heavy duty gas turbine platforms, has been incorporated into the 7FA.05 gas turbine. The compressor is based upon GE Aviation compressor technology practices. The 7FA.05 gas turbine technologies consist of 14 stages specifically modeled for a higher flow rate, enabling greater output. The airfoil design is based on the proven aerodynamic configuration of the GE5, GE10, 5002E and 6C platforms. The airfoils utilize a proprietary, three-dimensional aerodynamic shape for improved efficiency. The first three stages of the compressor contain variable stator vanes that provide the gas turbine with a wider operating envelope. The compressor flow path has been planned to accommodate inlet conditioning with improved leading edge erosion tolerance. The rotor is bolted steel construction with two sets of durable concentric tie bolts specifically planned to improve the aerodynamic flow path. The rotor blades and wheels incorporate a circumferential dovetail plan that permits removing the blades without pulling the rotor from the casing, thereby improving maintainability. The compressor casing has been built to match the rotor and the existing DLN2.6 combustor interface. The casings accommodate an advanced Blade Health Monitoring (BHM) system for stages 1 through 3. Additional borescope holes have been included for enhanced inspection coverage.
1. Source: ORAP; All rights reserved: SPS (2Q09-1Q10)
Table 2 identifies the major components and experience of the compressor technology that was leveraged from other GE platforms. Component VSVs Rotor Wheels Blades Casings Diffuser Bearings Comment 3 Variable Stator Vanes Bolted, 2 Tie Bolt Rings Circumferential Dovetails Increased Stage Loading Match Rotor and DLN2.6 Hybrid Radial Flow Path Non-integral w/fwd Case 4 = Materials Experience
Table 2. 7FA.05 model compressor experience
B/E
FA
FB
6C 4
H 4 4 4 4 4 4 4
GE10 4 4 4 4 4
4 4 4 4 4 4 4 4 4 4 4 4 4 4
4 4 4 4 4 4
Combustion
The 7FA.05 gas turbine will employ the proven DLN2.6 combustor. The combustor has more than 15 million hours and 400,000 starts of operational experience. Minor modifications to the DLN2.6 combustion system will be required for the improved output and efficiency. Upgraded fuel nozzles will allow for a higher fuel flow rate and the transition piece cooling flow has been improved. Combustion lab tests have demonstrated emissions, durability, operability, dynamics and exit profiles for these minor modifications. Component Liner / Flow Sleeve Transition Piece Caps End Cover Fuel Nozzles Comment DLN2.6 model TP cooling pattern adjusted for radial diffuser flow distribution DLN2.6 model DLN2.6 model Fuel injection peg adjusted for higher fuel flow rate 4 = Materials Experience
Table 3. 7FA.05 gas turbine combustor experience
6/7/9FA 4 4 4 4 4
Turbine Section
The turbine section of the 7FA.05 version capitalizes on the recent 7FA Advanced Hot Gas Path advancements. FB technology and experience flow have been used in the design. Noted features are: Proprietary, three-dimensional aerodynamic airfoil shapes for the S1N and S1B improving efficiency More efficient stage loadings between stage 2 and stage 3 Improved cooling and sealing for improved efficiency Improved clearances for improved efficiency Nominal Tfire increase that still remains well within the FA experience class FB materials have been employed for the stage 1 nozzle and stage 1 bucket while H System* material has been used for the stage 2 nozzle. The higher temperature-capable materials still operating in FA firing temperatures will further improve the successful experience of the 7FA wear modes for low cycle fatigue, oxidation and creep, thus supporting longer life and reduced repair costs.
The first and second stages of the turbine section will consist of minor modifications to the 7FA Advanced Hot Gas Path hardware to increase the flow passing capability. The third stage will utilize the 7F Syngas design. The turbine casing remains unchanged. Component Stage 1 Stage 2 Stage 3 Comment 7FA.04 version 7FA.04 version 7F Syngas version 4 = Materials Experience
Table 4. 7FA.05 gas turbine experience
7/9FA 4 4 4
7/9FB 4 4 4
6C 4 4 4
7/9H 4 4 4
GE10
Validation Plans
Component level testing is required to ensure boundary conditions are well understood in order to articulate sub-system design and system level interactions. The following are key subsystem test rigs that have been completed to support component level validation to ensure system level program success: Inlet rig inlet flow profile for R1 blade durability, performance VSV rig vane arm mechanical durability Combustion lab and rig combustion dynamics and profiles for life, emissions Compressor diffuser rig hybrid radial diffuser design for performance Turbine aero rig performance Exhaust diffuser rig performance and exit profiles System Level Testing will be required for the full validation of the 7FA.05 gas turbine and will rely on three key systems level tests. Compressor test full scale compressor characterization 7FA.04 HGP field test successfully instrumented field rotor test (completed in May 2009) 7FA.05 FSFL test Factory FSFL test of the 7FA.05 gas turbine
Compressor Testing
The compressor vehicle test of the 7FA.05 Gas Turbine is planned to start in the early to mid 2011 timeframe. This test is expected to be two-to-three months in duration. The test will be comprised of over 2600 data streams that will be supplied through an advanced slip ring. The data achieved by this test will support the validation of the following objectives: Aerodynamics mapping for performance Compressor blade and stator aeromechanics Compressor rotating stall effects during start-up Optimize the IGV / VSV schedule Measure expected inlet flow distortions Measure bleed valve sensitivities Compressor sub-system operation of the compressor exit diffuser Compressor tip clearance robustness IGV / VSV mechanisms Finalize VSV linkage lengths On-line water wash operation Flow and heat transfer assumptions Transient operation with fast start Torque measurement system
System Testing
The gas turbine test of the 7FA.05 Gas Turbine is planned to start in the late 2011 timeframe. This test is expected to be three-to-four months in duration. The test will be comprised of over 2800 data streams that will be supplied through two advanced slip rings. The data achieved by this test will support the validation of the following objectives: Gas turbine performance Compressor aeromechanics (as a result of compressor learning from rig test) Compressor to combustor interface Combustion operability and dynamics Combustion and gas turbine exhaust profiles Rotor / HGP life (thermals and stresses) Grid code response Transient operation with fast start Natural gas and liquid fuels OLWW nozzle positions Accessory (system pressures, cooling and sealing) Controls The gas turbine will be tested over the test plan illustrated in Figure 4 in terms of mass flow, physical speed, and load.
Mass Flow
60%
20% 20%
FSNL
Purge Dwell
80% Nm
100% Nm
Part-Speed Region
Figure 4. 7FA.05 gas turbine test plan
Exhaust
Inlet
Drive Train
Gear Box
Compressor Rig
Starter Motor
With this unique test stand configuration, GE will have the capability to fully validate and test heavy duty gas turbines as follows: Full scale compressor test rig that will allow for steady state and transient aeromechanics, performance and operability testing of the compressor subsystem. Variable speed/variable load capability of the gas turbine that allows for simulating off frequency operation and importance of grid code compliance response. Full-Speed Full-Load capability of the gas turbine. This allows for simulating the conditions and load environment and of the gas turbine with electrical grid load. Ability to test far beyond the expected field operation of a gas turbine.
Flexible Configuration Modular Design Capability Full Scale Compressor Full Load Capability Variable Speed Capability
Capability to independently and simultaneous test a compressor rig and gas turbine Rapid development, quick configuration change, modules on rail Eliminates the uncertainty of scale effects Simulates the operation of a gas turbine as expected in the field Capability to test beyond grid code requirements in terms of aeromechanics and controls Test ambient temperature effects relative to the compressor Ability to fully map compressor especially to surge line and beyond at full scale SS conditions Inlet throttle flow measurement accuracy especially at low flows, ASME flow nozzle and 36 valve Exit throttle ability to back pressure compressor to target any desired op-line point Can pull inlet vacuum <0.5 atm, reduces impact of surge Reduces work required to achieve highest pressure ratio points on compressor map Advanced integrated control system consisting of two Mark* VIe systems with distributed I/O Ability to accurately measure torque and load on shaft The rotor has been especially calibrated for twist and torque effects (Material Properties and Dimensions) Increases accuracy and reduces uncertainty CVR Test 7FA.03 Driver GT has 600 data streams, CVR rig has 2600 data streams FSFL Test 7FA.05 Driver GT has 2800 data streams, CVR rig has 1000 data streams Advanced slip ring technology 744 nodes per slip ring Advanced rig inlet design Lube oil Compressed air Electrical valves Liquid and NG fuel systems Full exhaust AO42
Ability to Run at Sub-atmosphere Inlet Conditions Controls Advanced Load Measurement Capability
Advanced Data Acquisition Capability the product of the validation program (i.e., data) Accessories
Performance and operability Combustion life (dynamics) Gas path temp profiles for HGP life understanding
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VI. Conclusion
GEs 7FA gas turbine is the most experienced F-class gas turbine in the world. The 7FA fleet has more units in service, and has accumulated more operating hours and starts than any other F-class gas turbine. GE has utilized the wealth of knowledge that comes from this F-class operating experience and combined it with technology from across GEs broad portfolio of heavy duty and aeroderivative gas turbinesas well as GEs aircraft engine modelsto develop the 7FA.05 version gas turbine. The 7FA.05 delivers increased output and efficiency, which are highly valued in todays competitive power generation segment, but does so without compromising the world-class operational flexibility, reliability, and availability of the 7FA. The improved performance and operational flexibility have enabled the 7FA.05 to become part of GEs ecomagination portfolio, a rigorous internal and third party environmental and operational evaluation. Prior to delivering the first unit to a customer, the 7FA.05 will undergo a comprehensive series of component level, subsystem level, and system level tests, culminating in a Full-Speed Full-Load test in a new world class test facility being constructed at GEs Greenville, South Carolina, gas turbine manufacturing and test center of excellence. This testing will enable GE to fully characterize the 7FA.05 under real-life conditions and beyond. GEs commitment to the 7FA gas turbine is a testament to the confidence GE has in this industry workhorse to continue to serve the wideranging needs of its customers in an ever changing and extremely competitive segment.
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IX. References
1. Availability and Reliability Source: ORAP; All rights reserved: SPS
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NOTES
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NOTES
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* Trademark of General Electric Company. 2011, General Electric Company. All rights reserved. GEA18457A (07/2011)