TRAINING SESSION 1

GAS TURBINE BASICS, UNIT TYPES,

APPLICATIONS & PRICING
An introduction to the basics of the industrial Gas Turbine
- heavy-duty and aero-derivative units
- the gas turbine generator package
- the auxiliaries
for the cogeneration, combined-cycle or peaking power plant; or for repowering.
Jim Noordermeer, P.Eng.
Noord Power Consulting Inc.
Presented at the 2018 Gas Turbines for Energy Network (GTEN) Fall Workshop in Ottawa – October 2018.
The GTEN Committee shall not be responsible for statements or opinions advanced in technical papers or meeting discussions.
GAS TURBINE BASICS, UNIT TYPES, APPLICATIONS & PRICING

GAS TURBINE CONCEPTS Combustor 3'

Ideal 3
The Basic Thermodynamic Fuel Actual Firing Temperature
3
Gas Turbine Cycle Load
Brayton Cycle – a continuously Compressor Turbine
P2

T-Temperature
operating process using air as the on Expansion
sti
working fluid, moving through State 2 m
bu
Points: 4 2 Co
1
 Air Intake (State 1): ambient air enters the unit 2' 4

 Continuous compression (States 1 to 2): the Compression 4'

compressor requires power P1
 Continuous fuel combustion (States 2 to 3): which adds heat
and small % of mass flow at relatively constant pressure 1
 Expansion back to atmospheric pressure (States 3 to 4): with the s - Entropy
turbine making shaft power and driving the compressor and a
load (or jet thrust via a nozzle per the below illustration)
2' Combustion
3
2 P2 3'

P-Pressure
Compression
Expansion

Ideal
Actual

4
P1
1 4'

V-Volume

Jim Noordermeer, P.Eng. 2018 GTEN Fall Workshop - Ottawa www.gten.ca

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Mechanical Operating Principles

Turbine Section (hot-section) and it’s power
output physically drives (rotates) the Compressor
Section (cold-section) which needs power to
operate.
Excess Turbine Shaft Power drives the load –
generator (or mechanical-drive pump/compressor)

Firing Temperature
Firing Temperatures (T3): over time, have
climbed from 1400 deg F to 2000~2200 and now
2600 F and beyond with better turbine section
materials, coatings and cooling methods
High T3 = improves power output & efficiency.

Pressure Ratio
Pressure Ratio (P2/P1); high ratio = high efficiency & specific
output (hp/lb/sec).
Gas turbine design pressure ratios vary:
 7.5:1 – smaller & older technology GT’s,
 35:1 ~ 40:1 – recent, most advanced GT’s.

Aircraft “Jet Engines” are also “Gas Turbines”

 Jet Engines: propulsion via change in DeltaV / momentum
 Turboprops Engines: propulsion via propellors
 Low-Bypass & High-Bypass Turbofan Engines: propulsion via
large Fans and jet DeltaV
All generally use high pressure ratio & high firing temperature =
minimum weight & frontal area.

Jim Noordermeer, P.Eng. 2018 GTEN Fall Workshop - Ottawa www.gten.ca

Noord Power Consulting Inc. Gas Turbine Basics
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Turbine Cycle Variations – of the “Basic Cycle”: Combustor

Fuel
3 Load
Reheat or Sequential Combustion – used in high-pressure ratio GT’s. Turbine
Compressor
Hot HP Turbine Section gases are reheated by combustion of additional fuel (3a).
2
Reheated gases enter into LP turbine section (3a to 4). 1 4
The reheat configuration:
Basic Cycle
 Increases LP Turbine output (fired to a similar temperature as T3)
 Raises the turbine’s final exhaust temperature (good for HRSGs)
 Increases simple-cycle power output
 Increases combined-cycle power output (HRSG and STG)

Fuel Comb 2
Comb 1
Fuel 3a
3

Compressor

2 Load
Turbine 4
1

Example: GE-Alstom GT24/26.

Jim Noordermeer, P.Eng. 2018 GTEN Fall Workshop - Ottawa www.gten.ca

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Turbine Cycle Variations – of the basic cycle:

Recuperated or Regenerated Gas Turbines
4
Generally for low-pressure ratio units with high firing temperatures.
An external regenerative heat-exchanger transfers heat from the Fuel Combustor
turbine exhaust to the compressor discharge air (before fuel is
2a 3
introduced).
Compressor Turbine
Regenerative Configuration:
 Saves fuel 2 Load
 Increases efficiency
1
 Low exhaust energy

Examples: Solar Mercury 50 / Abrams M1 / Micro-Turbines

Jim Noordermeer, P.Eng. 2018 GTEN Fall Workshop - Ottawa www.gten.ca

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Turbine Cycle Variations – of the basic cycle:

Inter-Cooled Gas Turbines

Combustor
For high-pressure ratio multi-shaft GT units.
Fuel
LP compressor air is directed to an external heat exchanger. 3 Load
Cooling medium (water or air) decreases air temperature and Turbine
increases flow density. The cooled air re-enters the HP compressor. Compressor
2
Intercooled Configuration:
1 2a 4
 decreases HP compressor power
 improves efficiency & specific output Intercooler

Example: 100 MW GE LMS100, w/ air or water cooling.

Jim Noordermeer, P.Eng. 2018 GTEN Fall Workshop - Ottawa www.gten.ca

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Turbine Cycle Variations – of the basic cycle:

Spraywater Cooling – similar to intercooling, evaporative cooling and/or fogging
Very clean water injected before the LP compressor, and between the LP & HP
LM6000 compressor sections of the multi-shaft aero-derivative GE LM6000 Sprint.
Systems are also available on ISI versions of the Siemens / Rolls-Royce Trent.
 Increases HPC mass flow
 Increased pressure ratio
 Increased power output & efficiency @ high ambients

Intercooled & Recuperated Gas Turbine

Rolls-Royce WR-21 marine drive unit.
 Special high-efficiency configuration.
 Exhaust recuperator & sea-water cooled intercooler.
 For interest only - there are no land applications (other than possibly trains).

Jim Noordermeer, P.Eng. 2018 GTEN Fall Workshop - Ottawa www.gten.ca

Noord Power Consulting Inc. Gas Turbine Basics
GAS TURBINE BASICS, UNIT TYPES, APPLICATIONS & PRICING

Basic Components of the Gas Turbine

Compressor Section:
Usually multi-stage axial configurations,
or centrifugal in the smallest units.
Each stage consists of a row of stationary
blades (stators) & rotating blades.
Pivoted-variable inlet guide vanes (IGV’s)
– industrial & aero-derivative units -
manage bulk inlet air flow.
Outlet guide vanes (OGV) & diffuser –
straighten & slow air stream prior to
entry into the combustor section.
Compressed air is bled out & used for
cooling purposes in hot sections.
Compressor air is bled out for startup (to
prevent surge) and part-load operation
and/or dry low-NOx control
IGV’s sometimes manipulated to keep
exhaust temperatures high for
cogeneration or combined-cycle steam
generation considerations.
Many aero-derivative units employ
variable stator vanes (VSV) to control air
flow and rotor speed in the higher-
pressure section.
LM6000 Compressor with variable bleed valves (VBV), IGV’s and VSV’s
Courtesy of GE Energy

Jim Noordermeer, P.Eng. 2018 GTEN Fall Workshop - Ottawa www.gten.ca

Noord Power Consulting Inc. Gas Turbine Basics
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Basic Components of the Gas Turbine

Combustor Section:
Generally multi-can (basket)
design or annular-ring design
For standard diffusion-
combustion systems (i.e. non
dry low-NOx), gaseous or
liquid fuels introduced via
nozzles located at the head of
each combustor can, or front
of combustion annulus
chamber.
Portion of compressor air introduced
directly into the combustion reaction
zone (flame); remainder introduced
afterwards – for flame shaping and
quenching to T3.
Water or steam injection: for
environmental or power
enhancement
Transition ducts / liners - carefully
shape the hot gases for the turbine
section
Fuel, steam and/or water injection
manifolds & hoses around the
combustor section circumference.
Current generation dry low-NOx (DLN or DLE) combustion systems use lean pre-mix
principle, frequently multi-nozzle (Siemens Ultra Low-NOx and GE LM shown).

Jim Noordermeer, P.Eng. 2018 GTEN Fall Workshop - Ottawa www.gten.ca

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Basic Components of the Gas Turbine

Turbine Section:
Usually multi-stage axial design.
Each stage includes a stationary nozzle row which
imparts correct angle to hot gases, for succeeding
rotating blades.
The most critical section of turbine = 1st few stages.
Nozzle & rotating blade exposed to “red-hot” gases at
design firing temperature – far in excess of acceptable
creep-fatigue limits for engineered alloys employed.

Plus, the rotating blade is required

to survive under high centrifugal &
mechanical stresses.
Internal cooling passages are cast
and machined into nozzles &
blade.
Raw or cooled compressor bleed
air (and some units employ
steam) is passed through to
maintain material temperatures at
acceptable limits.

Jim Noordermeer, P.Eng. 2018 GTEN Fall Workshop - Ottawa www.gten.ca

Noord Power Consulting Inc. Gas Turbine Basics
GAS TURBINE BASICS, UNIT TYPES, APPLICATIONS & PRICING

Turbine Section
Blades & Discs:

Creep-resistant directionally-
solidified (DS) & single-crystal
(SC) blade production technology
– introduced from the aircraft /
jet gas turbine world.

Thermal barrier coatings (TBC)

employed to protect aerodynamic
surfaces & materials from
corrosion, oxidization and erosion.

Jim Noordermeer, P.Eng. 2018 GTEN Fall Workshop - Ottawa www.gten.ca

Noord Power Consulting Inc. Gas Turbine Basics
GAS TURBINE BASICS, UNIT TYPES, APPLICATIONS & PRICING

Turbine Section
Stationary Sections:
Turbine row assembly, showing
blade attachments to the rotating
disk, and blade cooling air exit
holes

Turbine Nozzle w/ TBC & cooling

air exit holes

Jim Noordermeer, P.Eng. 2018 GTEN Fall Workshop - Ottawa www.gten.ca

Noord Power Consulting Inc. Gas Turbine Basics
GAS TURBINE BASICS, UNIT TYPES, APPLICATIONS & PRICING

THE GAS TURBINE ASSEMBLY (i.e. let’s put the sections together)
The Basic Gas Turbine Machine
Individual Compressor,
Combustor & Turbine sections
and their casings are bolted
together.
Supported via struts & baseplates
- to make a complete machine.
Rotating compressor & turbine
sections mechanically
interconnected.
Compression power is provided by
turbine section’s power output.
Excess turbine shaft power drives
pump, compressor or generator
via output shaft:
 Cold-end drive
 Hot-end drive
The 2/3 to 1/3 “Rule of Thumb”
60~70% of the Turbine Section’s power output
is used by the Compressor Section to drive it

The remaining 30~40% available as true shaft

output power, e.g. a typical nominal 50 MW single-
shaft industrial gas turbine produces ~150 MW in
the turbine section, gives ~100 MW to the
compressor section, and has 50 MW left to run a
generator

Jim Noordermeer, P.Eng. 2018 GTEN Fall Workshop - Ottawa www.gten.ca

Noord Power Consulting Inc. Gas Turbine Basics
GAS TURBINE BASICS, UNIT TYPES, APPLICATIONS & PRICING

F-Class Gas Turbine

Assembly
(175~225 MW)

Top-Half removed –
multi-stage compressor with
IGVs, multi-can combustor
with baskets, multi-stage
turbine section and exhaust
diffuser

Longitudinal Assembly
Drawing
Cold-End drive

Jim Noordermeer, P.Eng. 2018 GTEN Fall Workshop - Ottawa www.gten.ca

Noord Power Consulting Inc. Gas Turbine Basics
GAS TURBINE BASICS, UNIT TYPES, APPLICATIONS & PRICING

Gas Turbine Variations – from the single-shaft design

Power
Single-Shaft with PT – industrial & aero-derivative units Combustor Turbine
A single-shaft GT operates at the speed and firing temperature to keep Fuel
itself self-sustained (frequently called a “jet”, or “gas-generator”, for Load
convenience). HPT PT
Compressor
The jet’s exhaust gases pass to an aerodynamic-coupled free power
turbine (PT) which drives the load – at fixed (generator) or variable Gas
(mechanical drive) speed. Generator

Multi-shaft, with & without PT

Fuel Industrial units designed for variable-speed mechanical drive or derivatives
Load of aircraft engines.

HPT LPT Basic compressor & turbine sections divided into HP and LP units. HP and
LPC HPC
LP each operates at different speed – depends upon load & ambient
conditions. The LP compressor (LPC) is coupled to and is driven by LP
turbine (LPT). The HP compressor (HPC) is coupled to and is driven by the
turbine (HPT).
In some three-shaft machines, an intermediate compressor (IPC) & turbine
(IPT) also used, in between LP & HP sections (configuration not shown).
Fixed or variable-speed loads are
driven off LP shaft.
Fuel
Load Some units can drive off cold-end
or hot-end of LP shaft.
LPC HPC HPT LPT PT
In some cases, multi-shaft units
act as a “gas generator”, and a PT
is required to drive the load.

Jim Noordermeer, P.Eng. 2018 GTEN Fall Workshop - Ottawa www.gten.ca

Noord Power Consulting Inc. Gas Turbine Basics
GAS TURBINE BASICS, UNIT TYPES, APPLICATIONS & PRICING

AERO-DERIVATIVE & HEAVY-DUTY INDUSTRIAL GAS TURBINES

“THERMODYNAMIC COUSINS” – sharing the same basic cycle.
Aero-Derivative GTs – based on aircraft engines; usually low
weight / frontal area (generally inconsequential for industrial service)
The early-original jet engines had their nozzles removed & power
turbines (PT’s) installed for industrial service
Later-design turbo-prop & turbo-fan engines – industrialized by
redesign of the prop or fan takeoff drives’ or LP section; or by a PT.
Most aero-derivatives (compared to same-size industrial cousins):
 very efficient because of their high T3 and P2/P1 designs.
 less HRSG steam generation due to lower exhaust gas flows.
Major Maintenance – generally conducted by complete
removal of gas turbine from package – special lifting
frames required.
Modules disassembled into smaller components - LPC,
HPC, combustion module, HPT and LPT, etc.
Minor maintenance
activities – conducted
at site.
Major maintenance &
overhaul - unit
returned to certified
shop.
Lease engines available –
replaces original engine
while under repair.

Jim Noordermeer, P.Eng. 2018 GTEN Fall Workshop - Ottawa www.gten.ca

Noord Power Consulting Inc. Gas Turbine Basics
GAS TURBINE BASICS, UNIT TYPES, APPLICATIONS & PRICING

Heavy-Duty Industrial GTs – heavier and more-rugged than its cousin

Optimized to operate over narrow speed range & generally for base-load duty
Typically, the scheduled maintenance intervals are longer than aero units

Heavy multi-cylinder castings and fabrications.

Large bolted horizontal and vertical split joints.
Heavy built-up rotors & journal bearings.
Large solid couplings
Large baseplates and frames.
Major Maintenance – usually done at site:
 removal of top half cylinder
 removal of diaphragms and blade rings
 lifting and removal of the turbine rotor
 subsequent blade removal.

Jim Noordermeer, P.Eng. 2018 GTEN Fall Workshop - Ottawa www.gten.ca

Noord Power Consulting Inc. Gas Turbine Basics
GAS TURBINE BASICS, UNIT TYPES, APPLICATIONS & PRICING

COMPARISON – Aero-Derivative & Heavy-Duty Industrial Gas Turbines

Aero-Derivative Heavy-Duty Industrial
Performance Up to 50~65 MW. Up to 240 MW+.
Up to 41~45% efficiency (LHV). Up to 35~45% efficiency (LHV).
Generally, less waste heat Good waste heat opportunity.
opportunity from the exhaust gases. Large units with high exhaust temperatures allow reheat
combined-cycle
Fuel Aspects Natural gas to light distillates and jet Natural gas through to distillates and cheaper heavy or
fuels. residual fuels.
Most require relatively high gas Generally require lower gas pressures.
pressures. Expensive treatment of heavy / residual fuels is required.
Start-Up Quick startup – 5~20 minutes. 20 to 60 minutes depending on size.
Relatively low horsepower starters High horsepower diesel or motor starters, also some are
usually electro-hydraulic started by the motoring of the generator itself
Loading Quick loading, sometimes Slower loading, 1~10%/min
10~25%/min depending on size
Shutdown Many larger units require a short time Many units require 1~2 days on turning gear after
of motoring to cool internals after a shutdown, but most can be motored to assist quicker cool
trip, but can then be shutdown down

Some GT units like the GE LMS100 combine aero-derivative and

heavy-duty industrial aspects, utilizing sections from their LM
and industrial lines.

Jim Noordermeer, P.Eng. 2018 GTEN Fall Workshop - Ottawa www.gten.ca

Noord Power Consulting Inc. Gas Turbine Basics
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THE GAS TURBINE PACKAGE

“Packaging” completes the machine - needs to be
straightforward to install & commission; and easy to
maintain.
Driven Equipment
Typically:
 synchronous generators – rated per ANSI C50.14.
 process or pipeline compressors
 occasional use as large pumping sets for oil.
For cogeneration / combined-cycle – typically a Generator.

2-pole (3600 rpm) or 4-pole (1800 rpm) for 60 Hz.

Air-cooled, water-cooled (TEWAC) or hydrogen-cooled (the largest units).
Generator output voltages:
 600V for the very smallest GT’s,
 to 2.4 and 4.16 kV for the 3~8 MW class units,
 13.8 kV for the 10 MW+ units,
 27.6 kV for the 100 MW+ units.
Excitation System required for
voltage & power factor/var control –
brushless or static.

Gearbox: when GT output

speed doesn’t match generator
speed - double-helical or
epicyclic gearboxes

Jim Noordermeer, P.Eng. 2018 GTEN Fall Workshop - Ottawa www.gten.ca

Noord Power Consulting Inc. Gas Turbine Basics
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Gas Turbine Air Inlet Systems

Filtration, Silencing, Air Heating and/or Cooling
Critical to GT health, for noise mitigation and/or performance.
Filtration: high-volume multi-stage high-efficiency filtration
systems – capture atmospheric particles and prevent their
deposition on the bladepath
Inlet Air Heating: via coils or bleed air systems - for anti-icing;
inlet temperature / performance optimization; DLE control
Inlet Air Cooling; via coils – for inlet temperature / performance
optimization at higher ambient temperatures
Evaporative Cooling Systems & mist eliminators
Fogging systems & mist eliminators

Tuned inlet air silencers – absorb sound

& acoustic emissions from intake

Jim Noordermeer, P.Eng. 2018 GTEN Fall Workshop - Ottawa www.gten.ca

Noord Power Consulting Inc. Gas Turbine Basics
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Lubricating Oil Systems

Main, auxiliary and emergency lubricating and control oil (as required) systems – provided for gas turbine and driven
equipment.
Aero-derivatives – usually fire-resistant synthetic lube oils.
Power turbines, gearboxes & generators – mineral-based lube oils.
Most heavy-duty industrial GT’s have common lube oil system – turbine, gearbox & generator.
Lube oil – is cooled by aerial fin-fan coolers, or oil-to-water heat exchangers.

Fuel Systems
Aero-derivative & heavy duty gas turbines – use light-liquid or gaseous fuels
Only the frame units – operate on heavy fuel oils & crude oils.
Fuel control systems for gaseous and liquid fuels include:
 filters, strainers and separators;
 block & bleed valves;
 flow control/throttle and sequencing valves, manifolds and hoses.
For natural gas duty – sometimes reciprocating or centrifugal gas compression
equipment required, plus pulsation dampening equipment.
Complex dry low-NOx (DLE) units – some units require several throttle valves,
staged and sequenced to fire:
 pilot / ignition,
 primary,
 secondary and/or tertiary nozzle and basket sections (as applicable) of
the DLE combustion system;
All as required for startup/shutdown, speed ramps, and load changes. Several
fuel manifolds usually required.

Jim Noordermeer, P.Eng. 2018 GTEN Fall Workshop - Ottawa www.gten.ca

Noord Power Consulting Inc. Gas Turbine Basics
GAS TURBINE BASICS, UNIT TYPES, APPLICATIONS & PRICING

Acoustic and Weatherproof Enclosures

Most smaller industrial & almost all aero-derivative
GTG packages are pre-packaged - complete
drivetrain enclosed in acoustic enclosure(s); quicker
& easier to install. The turbine & generator
compartments are separately ventilated.

40~60 MW+ industrial /

heavy-duty GT machines are
generally too large to pre-
package.
Components shipped in
major blocks & assembled at
site.
Enclosures or buildings (if
required) are built around
the complete drivetrain.

Jim Noordermeer, P.Eng. 2018 GTEN Fall Workshop - Ottawa www.gten.ca

Noord Power Consulting Inc. Gas Turbine Basics
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Controls and Monitoring

Complex combinations of digital PLC and/or processor systems:
Woodward; vendor-proprietary systems; occasionally DCS-based
Systems include, manage, sequence, monitor and control:
 GT fuel control and speed/load control
 generator’s voltage, power factor / var control
 breaker synchronization, relay protection
 auxiliaries
 vibration, temperature & pressure monitors
 sequence of events recorders
 certified metering systems
 communication to plant DCS.
Miscellaneous Auxiliaries
 starting, purge and turning gear
systems
 inlet manifolds
 exhaust diffusers or plenums
 water wash systems
 water and steam injection (if required
 gas detection systems
 fire detection and CO2 suppression
systems
 battery and charger systems
 ventilation and heating
 exhaust expansion joint
 silencer & stack systems (simple-cycle)
 HRSGs for steam production
(cogeneration or combined-cycle)

Jim Noordermeer, P.Eng. 2018 GTEN Fall Workshop - Ottawa www.gten.ca

Noord Power Consulting Inc. Gas Turbine Basics
GAS TURBINE BASICS, UNIT TYPES, APPLICATIONS & PRICING

GAS TURBINE PRICING - from the 2018 Gas Turbine Handbook ($USD)
Simple-Cycle GTG Prices – not total “project cost”

Jim Noordermeer, P.Eng. 2018 GTEN Fall Workshop - Ottawa www.gten.ca

Noord Power Consulting Inc. Gas Turbine Basics
GAS TURBINE BASICS, UNIT TYPES, APPLICATIONS & PRICING

GAS TURBINE PRICING - from the 2018 Gas Turbine Handbook ($USD)
Combined-Cycle (CCGT) Prices – approximately the project cost for a “reference
plant” without typical options and site specific factors.

Jim Noordermeer, P.Eng. 2018 GTEN Fall Workshop - Ottawa www.gten.ca

Noord Power Consulting Inc. Gas Turbine Basics
GAS TURBINE BASICS, UNIT TYPES, APPLICATIONS & PRICING

GAS TURBINE PRICING - from the 2018 Gas Turbine Handbook ($USD)
Mechanical Drive Gas Turbine Prices – gas turbine only and does not include driven
equipment nor, the total “project cost”.

Jim Noordermeer, P.Eng. 2018 GTEN Fall Workshop - Ottawa www.gten.ca

Noord Power Consulting Inc. Gas Turbine Basics