The F Technology Experience Story: GE Power Systems
The F Technology Experience Story: GE Power Systems
The F Technology Experience Story: GE Power Systems
GER-3950C
GE Power Systems
The F Technology
Experience Story
Eric Gebhardt
GE Power Systems
Atlanta, GA
The F Technology Experience Story
Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
MS7001F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
MS9001F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Design Enhancements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MS6001FA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Emissions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Operational Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Compressor Issues and Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Tie Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
15th Stage Wheel Cracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
17th Stage Fillet Cracking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Turbine Rotor Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Turbine 2-3 Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Third Stage Subassembly Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Uprates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Future Evolution of the F/FA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Compressor Capability Offers Further Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Introduction History
Prior to 1987, the largest gas turbines (both 50 Gas turbines were first used for power genera-
Hz and 60 Hz) operated at firing temperatures tion in the 1950s, and were used almost exclu-
in the neighborhood of 2012°F(1100°C). sively for peaking duty. For this mode of service,
Combined Cycle plants were operating at effi- designs were required which featured low spe-
ciencies upwards of 45%. Reliability/Availabilty cific cost and good starting reliability.
had begun to reflect the maturing of the gas Through the 1960s and early 1970s, continuing
turbine in base load service, with fleet availabil- advances in gas-turbine efficiency, reliability,
ity between 85% and 95% depending on tur- and availability facilitated a wider range of
bine model and manufacturer. applications for gas turbines. As operating
In June 1987, GE introduced a new generation hours increased, fuel cost assumed greater sig-
of gas turbine – the MS7001F. The introduction nificance in optimizing machine design. The
of the MS7001F was driven by the demand for importance of this factor grew dramatically with
higher efficiency plants with lower emissions the rapid rise in fuel prices following the oil
and lower cost (per KW/Hr). When the crises of the 1970s.
MS7001F was first introduced projections were As operating (fuel) cost became more impor-
made that the unit would obtain 200 MW and tant in gas-turbine economics, technology
50% efficiency in a Combined Cycle Duty development was focused on improving effi-
Application. ciency, primarily through increasing firing tem-
Since that time the numbers of GE "F" perature. In 1981 the MS7001F program began,
Technology units in the world has grown to 146 planners realized that the larger gas turbine size
that were in operation at the end of 1999. It is would mean lower power plant specific cost,
estimated that there will be 239 in operation by and a higher firing temperature would result in
the end of 2000 (See Figure 1). higher combined cycle efficiency.
300 3500
Number of Units
250 3000
Hours of Operation
2500
Hours of Operation
Number of Units
200
2000
150
1500
100
1000
50 500
0 0
1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000
Figure 1. Cumulative number of units and hours in operation each year. 2000 values are estimated based on
sales and units in manufacturing.
In order to achieve the higher firing tempera- which were closely followed by the MS6001F
tures many changes would be required to the (which would be gear driven at 50 Hz or 60 Hz)
unit to ensure no adverse affects on mainte- (See Figure 2).
nance intervals. Key technologies had been The heart of the “F Technology” came from the
developed which would allow for this new First stage compressor aerodynamic design,
design. These included new compressor airfoil higher temperature capable materials and
designs which would allow for a higher inlet more sophisticated hot gas path component
mass flow, as well as new methods for large cooling circuit.
superalloy castings which would allow for more
efficient cooling of the buckets and nozzles. MS7001F
The one major factor against significant
From the beginning, the MS7001F develop-
advancement was the power generation indus-
ment program contained an extensive series of
try was in downturn. GE made the decision to
tests. These were grouped into three phases:
continue with the design despite the status of
(See Figure 2)
the industry at the time.
■ First were component and technology
Design validation tests. These tests included
combustor operation, bucket and
Prevailing economic factors resulted in the
compressor blade vibration tests, heat
decision to introduce the first “F” machine con-
transfer coefficient measurement and
figured to serve the 60 Hz market (MS7001F),
many others.
then follow with a 50 Hz product (MS9001F),
and finally flowing the technology to a size ■ Second was the factory test under load
demanded by industrial cogeneration and dis- with test points at full firing
trict heating (MS6001F). The MS7001F (60 Hz) temperature. An axial flow compressor
and MS9001F (50 Hz) programs were integrat- was used for the factory-loaded tests.
ed and had overlapping development cycles
7F No-Load Test
7F Loaded Test
7F Comm. Shtp.
7F Power Plant Constr.
7F CC Operation
9F Test - France
GT 25511A
Figure 2. Schedule of key milestones
■ Third in the series was the field test, The Greenville test confirmed the predicted
where full flow and full temperature compressor performance, efficiency, and oper-
could be simultaneously achieved. ational functionality.
Additional changes were also decided on to sup- During disassembly following the Greenville
port drive in industry for increased Reliability test, slight cracking was observed on four com-
and Availability. These changes were: pressor vanes. Analysis was performed and a
■ Dedicated accessory base skids that resolution was implemented prior to the unit
were arranged for easy access and being placed in operation.
powered by individual electric motors. The heavily instrumented unit from Belfort
This design was to minimize downtime experienced dynamic excitation on stages 14,
associated with all types of 15 and 16 stators during startup and accelera-
maintenance. tion from cold conditions. Although a modified
■ Axial exhaust was designed to reduce start-up procedure eliminated the condition,
the losses between the gas turbine exit changes were made in blade profiles to com-
and the heat recovery steam gen- pletely eliminate the possibility of vibration
erator (HRSG). problems on future units. All blades put in serv-
ice were of the modified design.
■ Cold end generator drive
configuration.
Design Enhancements
■ Two bearing design was adopted
The most significant impact which test data had
similar to steam turbines and
on the appearance of the “F” family of gas tur-
MS6001B/MS5001 gas turbines.
bines was the choice of a rotor designed with
IN706 material rather than the lower-strength,
MS9001F
M152. The design team recognized that ductili-
The MS9001F was introduced in 1989 and was ty of M152 could be reduced by exposure to the
designed using aerodynamic scaling from the environments of a turbine with high pressure
MS7001F. Fundamental component configura- ratio and high gas path temperature. As the
tions can be based on this scaling technique. effect of exposure of iron-based wheel alloys to
However, some phenomena are known not to turbine environments was more fully under-
scale. Their effects were investigated by the stood, the decision was made to increase the
same thorough analysis used in the preceding robustness of the rotor by applying a material
design, and the necessary adjustments were far less sensitive to exposure to high tempera-
made. ture. So the rotor was redesigned with lighter,
Initially there were two MS9001F units built yet stronger, wheels and spacers. In the process,
practically simultaneously. A unit with minimal the total depth of bolt holes in the rotor was
instrumentation was operated at no load in the reduced, hence the multiple-bolt construction,
Greenville factory, and a fully instrumented much like the MS5001 turbine rotor, in place of
unit was assembled in the Belfort factory. The the through-bolting used on the MS7001E and
instrumented unit later underwent fully-loaded similar machines.
testing in simple-cycle operation.
The outcome of the testing of the machines bility for all gas turbine products. Interim steps
resulted in tuning of other portions of the resulted in systems capable of 42 ppm and 25
design. These changes would result in better ppm. The F technology, because of high specif-
overall life of the units. The first rotating blade ic output, brings an additional benefit to the
of the compressor (stage zero) was re-tuned to environment. Because of the higher specific
raise a natural frequency. Blade clearances were output of high firing temperature machines,
adjusted to reduce the level of rubbing during less NOx and CO are emitted per unit of power
transients. The solidity of compressor stator produced for the same exhaust concentrations.
stage 17 was increased to eliminate a high vibra- Because of the increased efficiency, less fuel is
tory stress due to flow separation under some required for a given level of power production;
operating conditions. hence, F technology machines emit less CO2.
In order to ensure that the units would meet life Figure 3 illustrates the benefits of F technology
predictions temperatures were measured to given fixed emission standards.
confirm calculations. Data from the testing con-
firmed the calculations that were performed Operational Issues
and thus verified our parts life estimates that After more than five years of essentially trouble-
were made early in the design. free service and more than 150,000 fleet oper-
ating hours, a number of GE F class gas turbines
MS6001FA experienced compressor or turbine rotor dis-
Conceptual design of an MS6001F gear driven tress beginning in mid-1994. Ultimately, most of
version began in 1991. The objective was to the operating units were affected to some
bring the benefits of “F” technology to the mar- extent by these issues. Root cause was identi-
ket segment traditionally served by the MS5001 fied, resolutions were designed and implement-
and the MS6001B. An output in the range of 60 ed throughout the fleet in a manner designed
MW to 70 MW would represent a proportional to minimize the unavailablity to the operators.
increase in output beyond the MS6001B similar The issues encountered during this period did
to the increase of the MS6001B relative to the impact customers’ operations, but these obser-
MS5001. Since the MS6001FA was to be a gear- vations are important in assessing the implica-
driven machine, the grid frequency of the appli- tions to advancing technology:
cation was irrelevant in selecting scale factor. ■ “F” Technology Fundamentals were
The MS6001FA is a 2/3 scale of the MS7001FA. not root cause of issues. “F”
The design program began in 1993 and the first Technology Fundamentals include
unit was assembled in late 1995. high firing temperature and associated
high temperature materials, advanced
Emissions cooling or high mass flow compressor
Due to environmental concerns with the stages.
exhaust of the heavy duty gas turbine emissions ■ Issues were associated with features
criteria commonly specify a maximum concen- and processes applied to single
tration of NOx in the exhaust. During the “F” machines or a limited population.
programs, a parallel program delivered low- Turbine Rotor flexibility had fleet-wide
emission combustors for the GE product line. implications.
The goal was to develop single-digit NOx capa-
(F)
15th Stage
Through Bolts
new spacer, or in units with field modifications base, from whatever gas turbine product it
and cooldown cycle modifications. comes, can benefit multiple product lines.
Figure 7 shows the incremental evolution of the
Third Stage Subassembly Bolts E class machine. As the E class matured, a deci-
Two MS9001F and three MS7001F units experi- sion was made to introduce the F class
enced cracking of the forward end of the third machines—the 7F and its scaled versions, the 9F
stage subassembly bolts. Root cause analysis was and the 6F. Many factors drove this decision,
performed and it was found that under certain but once the F machines were introduced, tech-
operating conditions combined with low elon- nology advancement or operating experience
gations on the bolts that the bolts would relax on the F product line has helped drive further
causing high cycle fatigue. Conclusion of the evolution on the older E class machines, albeit
RCA was to revise the elongation process to in more gradual steps.
reduce variability and to change the bolts to a Design improvements for the “F” product line
different material to increase margin to event. are made incrementally, and based on proven
(See figure 5). materials, extensive laboratory or engine test-
ing, and operating experience. When the “F”
Availability technology was announced, uprate potential
At the beginning of the “F” Program, GE and an was projected. Immediately upon completion of
industry advisory board set product availability the prototype testing at the Greenville factory,
goals which were higher than had yet attained these uprates began. One of the projections
by any gas turbine. As can be seen in Figure 6, made was that the combined cycle efficiency
availability of the “F” units has followed the would be increased from the 50% cited in the
mature proven units. introduction paper, to 55%. The 55% level was
achieved in 1994 with the testing a MS7001F
Uprates unit in combined-cycle mode.
Gas turbine designers are obliged to pursue Uprates continue, as the technology becomes
opportunities for improving efficiency, reliabili- available and as experience on the high tem-
ty, and maintenance cost, in such ways as to not perature components of the “F” fleet remains
invalidate the experience base. This experience favorable. Table 1 shows the evolution of the
MS7001F machine. Each uprate has been
achieved without reducing inspection intervals
2-3 Spacer below those established by the original design.
Third Stage
The first uprate of the MS7001F simply took
Subassemble
advantage of the better than expected perform-
ance observed in testing. Firing-temperature
upgrades involved modifications to component
cooling and pressure ratio.
These include improved clearance and leakage
control achieved with the help of honeycomb
Figure 5. Cross section view of the turbine rotor seals - which have been used now for years in
showing affected components the MS9001E and MS7001EA machines. Figure 8
100
95
90
85
7B-E Fleet
80 6B
75 7F/FA
70
Years in Operation
Firing
Temp
60% CC Efficiency
“H” (F)
Firing Temp
2600
Combined Cycle Efficiency
55% Future
“F” Potential 2400
Upgrades
50% 2200
“E” 2000
45%
1800
40%
1970 1975 1980 1985 1990 1995 2000 2005
Year of Shipment
shows the evolution of the PG7231FA to the ing of H and other technologies; and, a recent
PG7241FA, illustrating the incremental F compressor mapping test are all key factors
enhancements that were incorporated recently that will be carefully weighed.
into the 7F product line.
Compressor Capability Offers
Future Evolution of the F/FA Further Options
As GE looks forward to the next steps in the In 1998 a compressor test was run to revalidate
continued evolution of the F/FA product line, a the operating surge limit for the F/FA com-
range of factors is being considered. The con- pressor. The results of this test indicated there
tinuing improvement in F reliability and grow- was significant additional capability in the com-
ing experience base; the development and test- pressor. Figure 9 shows how this development
9PPM
DLN 2.6 DLN 2.6 Combustor
Combustor
New EGV Arrangement
EGV Arrangement 9PPM DLN 2.6 Combustor
• Flexible Seals Stage 2 Bucket Hot
HGP Gas
SealingPath
New EGV Arrangement • Flexible Seals Hot Gas PathSealing
Stage 2 Bucket
•Stage
Scalloped
2 BucketShroud Improved
Improved Sealing
• Scalloped Shroud
• Mod
• Mod Cooling
Cooling Tapered Struts
Hole Pattern
Hole Pattern
Compressor Rotor Tapered Struts
Robust Compressor
Robust Compressor
Rotor
Rotor
Figure 8. Transition from PG7231 to PG7241 gas turbine illustrates incremental improvement philosophy
55
ncy 7FB 2600
cie
effi
Firing Temperature (F)
CC 2500
7FA
53
2400
ature
mper
T fir ing te 2300
G
51
2200
FA Compressor Test Completed
2100
1984 1986 1988 1990 1992 1994 1996 1998 2000 2002 2004 2006
Year
List of Figures
1. Cumulative number of units and hours in operation each year. 2000 values are estimated based
on sales and units in manufacturing.
2. Schedule of key milestones
3. Emissions versus firing temperature
4. Cross section of compressor rotor showing locations of components
5. Cross section view of the turbine rotor showing affected components
6. “F” Technology following proven technology
7. Incremental evolutions of “E” and “F” technology
8. Transition from PG7231 to PG7241 gas turbine illustrates incremental improvement philosophy
9. Evolution of the MS7001F
List of Tables
1. Evolution from PG7191(F) to PG7241(FA+e)