EUROPEAN GAS TURBINES SA Formation Chents INTRODUCTION TO GAS TURBINE UNITS SUMMARY GAS TURBINE PRINCIPLE.. 1) BASIC PRINCIPLE. 7 2) DESCRIPTION AND FUNCTIONNING OF A GAS TURBINE GAS TURBINE DEVELOPMENT AND US! 1) ABRIEF HISTORY 2) APPLICATIONS FOR GAS TURBINE ENGINES. 3) DIFFERENT MODELS OF UNITS MADE BY “EUROPEAN GAS. TURBINES". 4) EVOLUTION OF GAS TURBINE.. RUNNING. 1) STARTING 2) SYNCHRONIZING .. 3) LOADING 4) SHUTTING DOWN.. 5) COOLINGDOWN..... cesta 00 ene v GEC _ALSTHOMp 2 GAS TURBINE PRINCIPLE 1) BASIC PRINCIPLE AIRINLET ‘ow a exaust ‘compnesseo AIR (Some atone |e svsTEM stanTine vevice FUEL er) >| wrsine 2 toad ACCESSORIES ‘COMPRESSOR ROTOR Functionning of the different elements : Compressor: t \erease air pressure. Combustion : to increase the volume of air by heating it Turbine: to convert the thermal energy of gases in mechanical energy (as useful work on the rotor). ‘A rotating compressor acts as a fan to drive the working fluid into the heating system. The fluid is heated by the combustion system (burning a controlled supply of fuel in the air flow). The turbine acts as a windmil, being blown round by the flow to drive the compressor and an output load via a rotating shat. Note : The name "gas turbine” comes from the fluid passing through the turbine ; mostly it is air - in fact it is a mixture of air and the products of combustion. For steam turbine, the fluid is steam ; for hydraulic turbine it is water...pain 2) DESCRIPTION AND FUNCTIONNING OF A GAS TURBINE 2.1. The compressor It compresses the atmospheric air in about 10 times initial pressure (the compressor pressure ratio depends on what model of turbine). It is an axial flow compressor driven directly by the turbine (it is mounted on the same shaft than the turbine), raising the pressure of a continuous flow of working fluid by means of its blading geometry and motion. The axial compressor is built up of several stages, each of them consists of a disc of rotor blades followed by a ring of stator vanes. The number of stages depends ‘on the model of machine. An additional ring of vanes is fitted in front of the first stage as inlet guide vanes (IGV) to direct the flow to suit the first-stage rotor. The compressor casing has at least two extractions of air (depending on the model of turbine) for bearing sealing, cooling and pulsation protection. During start-up sequence, in order to avoid stall of the compressor, the bleed valves open to bleed the ‘compressor and maintain satisfactory operation and 1.G.V. are in closed position to reduce the air flow. The fluid (air) flows through an annular passage surrounding the central shaft, entering and leaving at opposite ends of the compressor rotor. 2.2 The heating system Compressed air from the compressor flows into the annular space surrounding the combustion chambers, from which it flows into the space between the outer combustion casings and the combustion liners, and enters the combustion zone through holes or louvers in each combustion liners. The largest part of this compressed air is used to dilute the combustion products and cool them to a safe temperature for the turbine. Note : The allowable metal temperature, at the turbine inlet, depends on what model of machine (between 900 °C and 1200 °C).p4in The combustion system supplies the fuel through the fuel nozzles, into each of the combustion chambers where it mixes with the combustion air and is ignited by the spark plugs. One major advantage of the gas turbine is the ability to burn a large variety of gaseous and liquid fuels, including those derived from coal, at high temperatures. ‘one combustion chamber, the remaining At that moment the spark-plugs ig combustion chambers are also ignited by crossfire tubes that connect the reaction zones of the combustion chambers. Then, chamber pressure causes the spark-plugs to retract to remove their electrodes from the hot flame zone. The hot gases from the combustion chambers enter into transition pieces attached to the end of the combustion chamber liners and flow from there to the turbine section. The high combustion temperature provokes an important heat expansion of the air. As more fuel is injected into the air flow, as higher is rising its temperature and as bigger becomes its volume. The increased air volume provokes a higher pressure in front of the turbine that results in a higher velocity through the turbine. This phenomenon allows to control the gas velocity and with it the output power by the variation of the fuel flow. 2.3 The axial flow turbine = The turbine is used to extract energy from a flowing stream of gas : in the axial flow turbine, the gas flows through an annular passage surrounding the rotating power output shaft, in a direction substantially parallel to the axis of the shaft. The turbine section is also built up of a serie of stages (the number of stages, two or three, depends on what model of machine), each is composed of a range of stator blades followed by a range of rotor blades. The purpose of the stator part is to convert the high pressure at its inlet into velocity at its outlet and to direct it correctly into the following range of rotor blades monted on the turning shaft. In order to accelerate the gas flow, the stator blades are shaped in form of curved nozzles with a large inlet section and a narrow outlet section. They produce a jet which is propulsed into the hollow side of the rotor blades. It will be the kinetic energy of this jet which is turning the shaft. As greater is the pressure drop through the turbine as greater will become the power supply. Due to their shape the stator blades are called NOZZLES. The rotor blades carry the name BUCKETS.psi GAS TURBINE DEVELOPMENT AND USE 1) ABRIEF HISTORY Gas turbine is a young technology. If steam turbines and diesel engines have been used for more than one century, the use of gas turbines for industrial power production dates only about forty years. The first gas turbines were made during the second world war for aeronautic propulsion. But it did'nt become interesting for power production until 1970s, it was used for peak hours (for emergency) because its quick start up and low maintenance. Afew dates : 1936 : First British aeronautical gas turbine. 1939: Experimental gas turbine in closed cycle by Escher Wyss : 2 MW. 1944: Gas turbine for marine propulsion by Elliott. 1960: GE launched frame 5 gas turbine. 1975: Gas turbine can deliver over than 80 MW (9001 B). 2) APPLICATIONS FOR GAS TURBINE ENGINES Gas turbine engines are most generally known for their use in aircraft, but they are also used in surface transportation and increasingly in stationary applications. The latter field is still expanding, while the aviation consolidating : The stationary uses are discussed here in the sequence = + applications in electricity generation «mechanical applications for oil and gas industry «use of exhaust heat for combined cycles.pen 2.1 APPLICATIONS IN ELECTRICITY GENERATION ‘A gas turbine is ideal for driving a generator. These units are suitable for use by national electricity generating authorities. The advantage of such units is that they can be distributed throughout the country in medium sizes, being located near the demand and thereby minimising transmission losses. 2.2 MECHANICAL APPLICATIONS FOR OIL AND GAS INDUSTRY ‘Some gas turbines are designed with two shafts : one part of the turbine is linked to the compressor (to drive it) and the other part is coupled to the load. The first part is called "the gas generator" and the other part is a free power turbine, coupled to the load and running in a different speed from that of the engine. The combination of the gas generator with the free power turbine makes a two-shatt engine, These two-shatt engines are extensively used by the oil and gas industry, which can afford to burn its own fuel at, sometimes, relatively low efficiency. ‘A major application is pumping oil and gas through pipelines over long distances, through deserts, arctics lands, sea and other remote places. As the pressure varies considerably in the pipeline, two-shaft engines are suitable for this duty (as the gas generator may then change speed with only moderate loss of efficiency to cater for the load variations).pan 2.3 USE OF EXHAUST HEAT FOR COMBINED CYCLES The relatively low efficiency of the gas turbine results from the high temperature remaining in the exhaust gas. The heat may be used to raise the efficiency by feeding the engine exhaust gas into a boiler, to drive a steam turbine unit and generate more electrical power. 1e or steam ‘Such cogeneration units give higher efficiency than either the gas tu turbine by itself. Note : The exhaust gas heat may have other uses : it may be used for example for drying processes, for heating the compressed air before the combustion process takes place (it is a closed-cycle gas turbine) or also with a boiler, but instead of producing more power, to produce steam for district heating... 3) DIFFERENT MODELS OF UNITS MADE BY "EUROPEAN GAS TURBINES” European Gas Turbine's position is a licensee of General Electric (U.S.A.). The company is entitled to manufacture the whole unit, including the critical parts in the hot gas path. 3.1 MS 5001 GAS TURBINE ‘The MS 5001 covers the range from about 19 to 26 MW (ISO conditions). Compressor has 17 stages and turbine has 2 stages. Designed and built for the power generation and mechanical drive markets, it is a single-shaft, combustion gas turbine built to rotate at 5100 Rpm and has long been the industry's standard. 3.2 MS 6001 GAS TURBINE ‘An evolution of the MS 5001 machine, the MS 6001 turbine provides 50 % higher output (about 38 MW in normal base duty). It rotates at the same speed as the MS 5001, main compressor has 17 stages and turbine has 3 stages.p Brn 3.3 MS 9001 E GAS TURBINE ‘The MS 9001 E is more powerful than the others : about 115 MW in base load. It has the same shape as frame 6 gas turbine but itis 1,4 time greater. 3.4 MS 9001 F GAS TURBINE Jointly developped by General Electric of the USA and European Gas Turbines SA, the Frame 9F is a two-bearing single-shaft, producing about 220 MW in base load. Start-up and run-up to ignition speed are carried out by the electrical generator operated as a motor supplied throughout this phase by a static frequency converter. 4) EVOLUTION OF GAS TURBINE Efficiency and power of a gas turbine can be increased by raising the turbine inlet temperature. So, one evolution factor is to build turbines that can run with higher temperatures without any loss of life-time (of course high temperatures can damage the turbine more : oxydation, corrosion, erosion and thermal stress). To accept that temperature we use materials which are more resistant and it is also necessary to improve the cooling of internal hot parts. In twenty years the inlet turbine temperature has been increased from 800°C to 1100°C and soon it will reach more than 1250°C with the new MS 9001 F GT on base load.pon RUNNING ‘A package power plant, as supplied for most installations, is based on a single-shaft, simple cycle, heavy duty gas turbine unit driving a generator. Fuel and air are used by the gas turbine unit to produce the shaft horse power necessary to drive certain accessories and ultimately the driven load generator. The inlet end of the rotor shaft is coupled to an accessory gear who have internal shatts to Grive the fuel pump, lubrication pump, and other system components. These elements are in charge of essential functions for turbine running : lubrication, cooling, supplying fuel and atomizing air for combustion, and so on... 1) STARTING Starting the gas turbine involves special starting devices. An electrical motor or a diesel engine rotates the shaft (it is a rigid shaft so starting device rotates also the generator rotor) through a torque convertor. When the speed is sufficient to give enough air flow, the combustion chambers are fired. The torque given by expansion is more and more important and helps the acceleration of the turbine. The starting engine takes part in this operation until the turbine has overrun the autosustentation speed (when the power supplied by the turbine is above the power consumed by the compressor). When the turbine speed becomes greater than the starting engine speed, they are automatically separated. The turbine goes on accelerating until the nominal speed is reached. When the unit is ready to be synchronized to the network the starting sequence is complete, it has reached Full ‘Speed No Load. (FSNL)p 10/1 2) SYNCHRONIZING For synchronizing, the unit is brought to the network speed. Once the gas turbine has been synchronized either manually or automatically, it can be loaded by several loading sequences. But on startup if no load is selected, the unit is loaded automatically to the spinning reserve ; like 1 or 2 MW, just enough to avoid reverse power. 3) LOADING 3.1 Base load : This is the normal maximum loading for continuous turbine operation as determined by the turbine exhaust temperature level. Base load duty is characterized by long periods of continuous duty at near-nominal rating. The unit must be reliable, without risk of premature malfunction of turbine or auxiliary components. Although this type of operation causes the least overall damage to the turbine, it has an effect on the equipment design. 3.2 Preselected load : The preselected load point is adjustable from “spinning reserve" to “base”. It is normally below the base load point. The load will be controled at this value. 3.3 Peak load : Peak load is the maximum turbine loading permitted for relatively long duration, emergency power requirement situations consistent with acceptable turbine parts life. This load is determined by turbine exhaust temperature level.pitin 4) SHUTTING DOWN ‘There are two causes of shutdown : «the normal shutdown, which is initiated by manually operating the stop switch or by some mechanical or regulation problems, through protection devices. The normal shutdown procedure will follow automatically through generator unloading, turbine speed reduction, fuel shut-off at part speed and initiation of the coolingdown sequence when the unit stops. « emergency shutdown (we call it “trip") which is initiated by depressing the emergency stop pushbutton or by some mechanical or regulation important problems, through special devices. 5) COOLINGDOWN Immediately following a shut-down, the rotor is rotated to provide uniform cooling. Uniform cooling of the turbine rotor prevents rotor from bowing, rubbing and imbalance. The turbine can be started and loaded at any time during the coolingdown cycle.