Gas Turbine System Part 1 Gas Turbine Proper

Purpose
Used to generate electrical power for transmission to the grid. Prime mover of the Electrical Generator

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Model 7FA Rated output of 200,000 kva at a power factor of 0.85 Real power output is

200,000 kva x 0.85 pf = 170 MW

Actual output can be limited by generator temperature. Uses Dry Low Nox Burners (version 2.6)

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Recall the simplified figure of the Gas Turbine Air is compressed, ignited (combusted), and expanded before flowing through an HRSG. Inlet air filter assembly is used to clean the air

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The inlet filter cleans the air and the ducting straightens the air flow into the compressor, eliminating vortexes and other disturbances.

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Inlet air heating coils are used as anti-icing on high humidity, low temperature days. Failure to warm the air will result in icing on the compressor blades. This reduces GT efficiency, however less problems than ice flow in the compressor.

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Inlet plenum has a set of IGVs that are adjusted during startup and shutdown to protect the compressor Protection is from surging and stalling of the airflow. Each stage of compression consists of a rotating stage and a stationary stage.

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Air flows from compressor discharge, backward along the combustion can and into the combustion area. Mixed with fuel gas for combustion. Some air is used for cooling. Combustion is sustained.

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Dry Low Nox combustors create a lean air mixture, causing lower flame temperatures and lower NOx Emissions. Turbine section receives hot gasses Heat energy in the air mass works to rotate the gas turbine shaft.

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Each stage of the turbine (3 total) consists of a row of nozzles and buckets. Each nozzle, the kinetic energy of the flow is increased with an associated pressure drop. This converts the heat to useful work. Force on the blades rotates the shaft.

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From the last stage blades, the exhaust gas is sent through the HRSG before being sent to the atmosphere.

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The gas turbine has several sub-systems associated with it.

Lube Oil CO2 Fire Protection Water Wash Inlet Air Filter Inlet Air Heating Air Processing Ventilation Hydraulic Fuel Gas

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GT consists of:
18 stage axial flow compressor 14 chamber, can type combustor 3 stage axial flow turbine.

Mounted on vertical supports, both forward and aft. Aft supports are air cooled.

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Compressor Axial flow refers to the air flow along the axis. Figure to the left illustrates the comparison between an axial flow compressor and a centrifugal compressor. Axial flow is used in this application due to large volume of air flow.

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Each stage consists of a rotating set of blades and a stationary set of blades. Rotor rotates in the compressor casing and holds all rotating blades. Stator blades are mounted in casing. Air flows between them.

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Picture to the left illustrates a typical gas turbine rotor assembly. Larger blades are located on the first stage and force it rearward. As the air is compressed, less area is needed to compress the air, so the blade size decreases.

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Process continues through each successive stage Pressures are raised to 10-15 times the inlet pressure. Air flow is dependent on the physical size and speed of the machine. Remember 2/3 of the power produced by the GT is used to drive the compressor.

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Therefore a 1% gain in compressor efficiency produces a 2% gain in shaft output. Likewise in the reverse direction. Blades must be kept clean (water wash) to maintain capacity.

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Most notable indication of dirty blades will be reduced output on the Generator. However, pressure transducers will allow the operator to monitor discharge pressure.

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IGV PINION GEARS IGV RING GEAR

IGV's

1 STAGE BLADES

ST

ND

STAGE BLADES

COMPRESSOR ROTOR

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Compressor rotor blades are made of Stainless steel and are individually attached to the compressor rotor. Air foil shape Stator vanes are constructed of steel. Also air foil shaped to allow smooth airflow.

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Compressor Casing Constructed of Aluminum Houses the gas turbine compressor and provides mounting for stator vanes. Annular passages are constructed in the casing at the outlet side of the 9th and 13th stages. Air is extracted from 9th stage during startup, acceleration, and shutdown for pulsation protection.

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Air is extracted from 13th stage and compressor discharge for cooling purposes of the turbine 1st and 2nd stages. Discharge air is also routed to the inlet air heating system for anti-icing (highest temperature air). Approximately 25% of the air from the discharge of the compressor is used for combustion.

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IGVs Set of vanes used to pivot on axis to regulate air flow into the compressor This provides pulsation (stall) protection during startup and shutdown. Hydraulically actuated using a feedback loop of vane angle position. Linkage, mounted on the side of the machine actually pivots the IGVs.

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The hydraulic actuation of the inlet guide vanes is illustrated on G.E. System Drawing No. 0469. The system consists of servo-valve 90TV-1, LVDT position sensors 96TV-1 and 96TV-2, and hydraulic dump valve VH3-1. The hydraulic oil for the IGV originates from the Hydraulic Supply System, GE System Drawing No. 0434. The IGV Trip Oil System as illustrated on G.E. System Drawing No. 0418. When the IGV trip solenoid valve 20TV-1 is energized CLOSED, its drain port is blocked; thus providing trip oil pressure to the IGV system. As long as trip oil pressure is available, the dump valve (VH3-1) shifts to the 'operating' position. The controlled positioning of servo-valve (90TV-1) will then port hydraulic oil through the dump valve to operate the variable inlet guide vane actuator.

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During startup and shutdown, the IGVs are held in the full closed position. This reduces the amount of torque required by the starter and the amount of air drawn into the compressor.

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When the Temperature corrected speed is reached, the inlet vanes open slightly to increase airflow to the compressor. Corrected speed is a value of rotor speed and inlet air temp.

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When less than 20% generator load, the IGVs are in the minimum position. 0% open represents 14% open of the vanes. They are never completely shut.

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The IGVs are then opened to the minimum full speed position, around 48, until the temperature of the exhaust gas increases to within 10F of base load temperature.

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This method produces a higher exhaust gas temperature for a longer time while ramping to base load. This chokes the turbine, cuts down on cooling.

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The increases the exhaust gas temperature, thus increasing and maintaining steam production and superheat at less than base load.

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In simple cycle mode, not worried about steaming, just about mass flow through the compressor, so ramping open takes place a lot sooner. Full open angle is about 89 - 100%

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Speedtronic calls the simple cycle mode - IGV Temperature Control Off Combined Cycle Mode is IGV Temperature Control ON Not an option here.

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Surge and Stall When less than synchronous speed (3600 rpm), the aerodynamics of the compressor blades do not promote smooth progression of air through the compressor.

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Not conducive to low speed or low flow conditions. Surge results when the air flow stalls across the compressor blades. Can be minor or severe.

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Compressors are protected from surge and stall by

Controlling air flow into the compressor IGVs Bleeding air from the compressor in one or more stages (9th / 13th stages).

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Bleed ports are equipped with open/close valves (VA-1/2). Open at less than 95% speed and close at greater than 95% speed. Bleed air is piped to turbine exhaust.

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Bearings and Seals Rotor is supported at the forward end by Bearing No. 1 Bearing No. 2 supports the Aft End. Seals are located on each side of the bearing cavity to prevent leakage. Seals are under vacuum, keeping oil in.

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Combustor 14 individual reverse flow combustion chambers located circumferentially around the gas turbine. Combustion air enters the combustion chamber at the center of the unit. Air flows upstream (backwards/reverse) along outside of the liner cap. The combustion liner helps meter the amount of air into the combustion area.

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Liners Openings along the length provide a film of air for cooling the walls of the inner liners and caps. 14 chambers 2 have spark plugs (2/3) 4 have flame detectors (11,12,13,14).

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Flame is started with the retractable spark plug. Flame is propagated using crossfire tubes. Crossfire tubes connect all of the primary zones of each adjacent combustion chambers.

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Nitrogen Oxides Formed in the combustion process

Thermal NOx Most Prevalent Fuel NOx not prevalent when firing natural gas.

Thermal Nox is generated by the high temperature reaction between nitrogen in the atmosphere (78%) and oxygen in the air. Highly dependent on temperature

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Ox

= 1 Oxygen Molecule = 1 Nitrogen Molecule

N Ox N

= Nitric Oxide = Nitrogen Dioxide

Ox N N Ox N N Ox Ox N N N N N N Ox Ox N

N Ox Ox N Ox N Ox N N Ox N N Ox Ox N Ox Ox N N Ox N

THERMAL DISSOCIATION

N Ox N Ox

AMBIENT AIR
79% Nitrogen 21% Oxygen

NITROGEN OXIDES
Nitric Oxide Nitrogen Dioxide

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At atmospheric condition, nitrogen (N2) and Oxygen (O2) are quite stable. When exposed to heat, the molecules break apart thermally dissociate The unstable atoms combine with each other in forms of NO and NO2. About 95% is NO colorless and odorless About 5% is NO2 brownish color and odor

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Reducing NOx Emissions Burning of fuel happens in three distinct flames:

Diffusion Flame Air/Fuel mixed and burned simultaneously Lean Premix Flame Air and fuel are premixed before point of combustion. Partially Premixed Combination of diffusion and premix flame. Fuel is injected far enough up stream to mix fuel prior to combustion

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Older turbines used only diffusion flames. Requires rich fuel to air ratios Made for extremely high temperatures. High NOx emissions. Need to Lower emissions due to Clean Air Act. Injection water and injection steam Dry Low Nox combustors lower the flame temperatures, without affecting horsepower.

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Dry Low Nox combustors are founded on the principal that the fuel air ratio of any combustion process affects (DIRECTLY) the flame temperature. Lean fuel air ratios produce lower temperature flames than rich air to fuel ratios.

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Reducing air fuel ratio too low will result in loss of flame. Lean air fuel ratios are not permissible with diffusion burners. Premix the air and fuel before burning.

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The fuel is injected in multiple ports and stages inside the combustor, well in advance of the flame zone. Lower flame temperatures, result in less thermal disassociation, thus NOx formation

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DLN burner has one zone of combustion, however introducing the fuel in stages and different locations promotes premixing of the fuel and air

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Combustion control by the Speedtronic is dependent on the flame detectors, as well as the turbine firing temperature. This is used to sequence the fuel into the turbine.

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Speedtronic only indirectly calculates turbine firing temperature based on exit temperature (leaving the turbine). This is based on thermodynamic principles. DLN uses six nozzles per can.

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Q PM2

PM3

PM1

PM1 - centrally located nozzle PM2 - 2 outer nozzles, adjacent to crossfire tubes. PM3 3 outer nozzles positioned around the remainder of the combustor.

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Q PM2

PM3

PM1

Q Fuel pegs located circumferentially around the combustor can, upstream of the premix nozzles. Fully sequence progressing through 8 stages before reaching full load.

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Q PM2

PM3

PM1

The primary controlling parameter is the turbine firing reference temperature (TTRF1) Refer to pages 16 and 17 for explanation of sequencing.

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Mode Start 0 Nozzles in Use 0 PM1 and PM2 Description of Operation No fuel is admitted. Fuel is admitted to the combustor can for initial firing and crossfire. PM1 = 30% fuel flow PM2 = 70% fuel flow PM3 = 0% Q=0% Fuel is admitted from crossfire until approximately 95% speed (3420 rpm). PM1 = 0 % PM2 = 100% PM3 = 0% Q = 0% Fuel is admitted from 95% speed (3420 rpm) to Full Speed No Load. Exhaust Temp spreads should be below 120F. PM1 = 100% PM2 = 0% PM3 = 0% Q = 0% Synchronization to the grid is possible. At 1600F 2000F, fuel will be split among PM1 and PM2. At 2000F, fuel will be split between PM1 and PM3 manifolds. At 2170F, fuel will transition to PM2 and PM3, before admitting gas to Q. This only occurs briefly. At 2170F, fuel will transition to Q. PM2 and PM3 are already open. At 2220F, fuel will flow to all four nozzles.

PM2

PM1

3 4 5

PM1 and PM2 PM1 and PM3 PM2 and PM3

5Q 6Q

PM2 and PM3 and Q PM1 and PM2 and PM3 and Q

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Q PM2

PM3

PM1

Ignition and Flame Distribution 2 spark igniters or spark plugs. High voltage spark when energized which ignites fuel. After the LCI has begun rotation a purge cycle begins.

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Q PM2

PM3

PM1

After a few minutes, the LCI drops out, unit coasts to ignition rpm, about 300 rpm then the igniters start sparking. Flame is generated and propagated through the crossfire tubes.

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Q PM2

PM3

PM1

Since the Brayton cycle is continuous flame will always be present. Spark Plugs retract. LCI will continue to accelerate turbine until full speed. LCI drops out at 95% speed.

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Q PM2

At higher than 95% speed, the turbine and firing is what raises the turbine speed. Reaches full speed, no load condition.

PM3

PM1

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Turbine Expansion As gas expands, both thermal and kinetic energy of combustion gasses is converted to mechanical energy. Use impulse and reaction principles, illustrated on the left.

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Turbine consists of
Turbine Rotor Turbine Stator Exhaust Frame Exhaust Diffuser

Turbine consists of forward and aft wheels. Spacers between wheels All are mated with a tiebolt construction.

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Due to pressure reduction resulting in energy conversion, the size of buckets are increased through the successive stages to accommodate the gas flow. Less pressure, more volume.

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Fir tree-shaped dovetails that fit into the cutouts in the turbine wheels. 2nd and 3rd stage buckets are shrouded at blade tips to increase turbine efficiency minimizing tip leakage.

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Turbine Stator Nozzles Similar to the rotor stages, these also increase in size Labyrinth seals prevent leakage along the shaft. Horizontally split along casing line.

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Turbine Shell and Exhaust Frame Hold the stator nozzles in place and control turbine clearances. Cooling is provided to control size of GT shell and thus leakage past the blades.

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Cooling provided by two exhaust frame blowers. 75 hp motors This prevents thermal growth of turbine, maintaining alignment. #2 bearing cooling provided by two 7.5 hp blowers.

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Turbine Cooling Increased firing temperatures and mass flows have increased turbine output. These are possible by better

Blade and nozzle designs Materials Improved Cooling

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Cooling air supplied by compressor discharge. Flows out of blades and into the exhaust duct. 1st and 2nd stage cooling is same 3rd stage is not cooled because temp is already low.

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Turbine nozzles are cooled with compressor discharge air. First and second stage nozzles are cooled by internal impingement and external film cooling. See leading and trailing edge holes.

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Turbine rotor cooling is to promote reasonable temperatures and longer service life. Turbine cooling is monitored using the wheelspace temperatures. Detectors are located in each wheelspace for remote indication.

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THERMOCOUPLE TT-WS1AO-1 TT-WS1AO-2 TT-WS1FI-1 TT-WS1FI-2 TT-WS2AO-1 TT-WS2AO-2 TT-WS2FO-1 TT-WS2FO-2 TT-WS3AO-1 TT-WS3AO-2 TT-WS3FO-1 TT-WS3FO-2 WHEELSPACE 1st Stage Aft Outer 1st Stage Aft Outer 1st Stage Forward Inner 1st Stage Forward Inner 2nd Stage Aft Outer 2nd Stage Aft Outer 2nd Stage Forward Outer 2nd Stage Forward Outer 3rd Stage Aft Outer 3rd Stage Aft Outer 3rd Stage Forward Outer 3rd Stage Forward Outer TEMPERATURE 950F 950F 800F 800F 950F 950F 950F 950F 800F 800F 850F 850F

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