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THE AMERICAN SOCIETY OF MECHANICAL ENGINEERS

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the Technical Division, and the author(s). Papers are available from ASME for nine months
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Printed in USA.
Copyright © 1985 by ASME

Design and Development of the General Electric LM5000


Industrial Package Power Plant
R. L. CASPER
Marine and Industrial Engines and Service Division
General Electric Company
Evendale, Ohio

J. C. RUCIGAY
Gas Turbine Division
General Electric Company
Schenectady, New York

ABSTRACT Table I

A new 33 MW power generation unit utilizing a proven CF6-50 PGLM5000A PERFORMANCE


aircraft-derivative gas generator driving a new power tubine has been
designed, manufactured, and packaged by the General Electric Company. Natural Gas Distillate
This paper describes the development and test of the gas turbine and its Generator Frequency, Hz 50 60 50 60
integration into a complete package power plant, with emphasis on electric Output, kW* 31 820 31 820 31 820 31 820
utility and cogeneration applications. Heat Rate, LHV**
Btu /kWh 9 700 9 615 9 775 9 685
INTRODUCTION kJ/kWh 10 235 10 140 10 310 10 215
Exhaust Flow
Engineering tests on the General Electric Co. LM5000 gas turbine 275 268
lb/s 275 268
were recently completed. The LM5000 design is derived from the CF6-50 kg/s 125 122 125 122
aircraft engine and directed toward worldwide applications for electric Exhaust Temp.
power generation and cogeneration installations. The gas turbine is in- °F 791 797 805 812
tegrated into a complete package power plant incorporating many features °C 422 425 429 433
of the LM2500 and heavy-duty gas turbine power plants. Among the Conditions: ISO, continuous baseload duty, standard inlet and exhaust losses.
benefits of this application of aircraft engine design philosophy to industri-
al gas turbines are high simple-cycle efficiency, high power-to-weight ratio, Guaranteed rating at generator terminals.
and direct-drive capability for either 50 or 60 Hz power generation. Com- Gu aranteed heat rate a v e r age engine heat rate is 3% b etter.
plete testing of the package power plant under field conditions is
scheduled to commence in late 1985. This paper, then, includes both a i.e., high-pressure turbine blades and vanes, require more frequent re-
description of the gas turbine and package power plant and a summary of placement or repair than other gas turbine components. Hot section
the engineering tests. repairs are normally accomplished in conjunction with planned mainte-
DESIGN OBJECTIVES nance intervals identified as hot section repair intervals. Table 3 shows
the time between hot section repair objectives for the LM5000 based upon
The primary design objective was to provide a high-efficiency electrical various operating conditions.
power package for either industrial or electric utility use in either simple-
cycle or cogeneration configurations. Gas or distillate fuel operating capa- Other gas turbine components are intended to have an operating life in
bility was to be available with the achievement of acceptable exhaust gas excess of 160 000 h. The required intervals for gas generator overhauls
emissions levels by means of water or steam injection. are normally established based on an evaluation of system performance
parameters monitored during operation. Overhaul of the power turbine is
Performance not usually required within the operating life expectancy.
Table 1 shows the typical performance parameters for both 50 and Availability and Maintainability/Servicability
60 Hz simple-cycle applications at International Standards Organization
(ISO) continuous baseload duty conditions with standard inlet and exhaust Another design objective was to provide high availability consistent
losses. Figure 1 shows a typical power performance vs. ambient tempera- with the cogeneration users' needs for continuous process plant operation.
ture curve. Use of redundant systems and sensors were specified to provide a high de-
gree of reliability. To minimize downtime, the package power plant
Table 2 shows typical performance data for cogeneration applications design was optimized to facilitate on-site maintenance and rapid installa-
requiring combinations of electrical power and process steam. tion or removal of the gas generator or power turbine. Routine mainte-
nance and inspections, including hot section repair of the gas turbine sys-
Operating Life
tem, are to be achieved without removing the gas turbine from the pack-
As with any gas turbine intended for industrial applications, operating age enclosure. Use of the lifting and translation equipment provided in
life expectancy is a necessary consideration, not only for hot section com- the module package will enable removal or replacement of the gas genera-
ponents but also for the combustion air compressors and the load turbine. tor for overhaul. Maintenance of auxiliary system components requiring
Because of their adverse operating environment, hot section components, periodic cleaning, such as filters and coolers, is intended to be achieved

Presented at the Gas Turbine Conference and Exhibit


Houston, Texas—March 18-21, 1985

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0

40 with the gas turbine in operation. Use of the Speedtronic MMark IV con-
100% Speed 3600 rpm trol will allow safe diagnostic monitoring and repair while the turbine is
operating.
38 Estimated Average
Future Growth
Engine
Baseload rating is established at an average high-pressure turbine inlet
to 36
CI
temperature of 2112 °F (1158 °C). With the development of advanced
C turbine component materials and cooling techniques, gas turbine firing
temperatures can be increased to yield improved turbine efficiency and
E 34
power output. The LM5000 can realize an approximately 4% increase in
I output and a 0.3% increase in simple-cycle efficiency for every 20 °F in-
32 crease in firing temperature.
Steam injection
C
(0 30 General Electric studies to improve LM5000 output and thermal
efficiency via steam injection are currently underway. Steam injection in-
Q) creases mass flow while reducing exhaust N0^ emission levels. Selective
28 placement of the steam into the gas turbine yields improved turbine com-
cC ponent cooling, thus allowing increased firing temperatures. Preliminary
predictions indicate that a 35% increase in power output and a 10-11% im-
26 provement in thermal efficiency may be achieved through steam injection.
Current plans are to develop the steam injection capability for testing
0
under field conditions in early 1986.
24
Reverse rotation

22 The design flexibility of the power turbine gas path components per-
mits opposite rotation of the output shaft through the use of interchange-
—60 —40 —20 0 20 40 60 80 100
able blades and vanes, thus providing compatibility with a broad spectrum
Ambient Temp., °F (Compressor Inlet) of load devices without resorting to reversing gears. Use of a double-
ended generator, driven by an LM5000 at each end, is a typical example
Figure 1. PGLM5000A Performance. of the design flexibility.
DESIGN BASIS
Gas Turbine
Table 2
The LM5000 gas turbine is based upon the CF6 family of high-bypass-
POWER AND STEAM GENERATION
ratio, turbofan engines used on wide-body commercial air transports. The
WITH EXHAUST HEAT BOILERS
hot gas generator utilizes the core engine components of the CF6-50, i.e.,
B oile r Ty pe
the high-pressure compressor, the combustor, and the high-pressure tur-
Supplementary Fully bine (Figure 2). The gas generator low-pressure compressor is it
Unfired Fired Fired modification of the CF6-50 booster which replaces the aircraft engine fan-
Gas Turbine stage with two new compressor stages. The use of the three aircraft en-
- Output KW 27 300 27 040 26 650 gine booster stages in combination with these two new compressor stages
- Fuel MBTU/h 298.0 298.0 298.0 provide the same pressure increase as the CF6-50 at the inlet to the high-
MJ/h 314 330 314 330 314 330
pressure compressor. The low-pressure turbine section of the gas genera-
- Exhaust Flow Ib/h 887 600 887 600 887 600
Kg/h 402 615 402 615 402 615
tor is uniquely designed to match the power requirements of the low-
- Exhaust Temp °F 818 820 823 pressure compressor.
437 438 439

Recovery Boiler i
- Fuel MBTU/h 0 165.5 824.0
MJ/h 0 174 569 869 155
- Steam Output
160 psig - 371 °F klb/h 108.2 - -
420 psig - 655 °F klb/h 83.4 228.0 -
630 psig - 755 °F klb/h 74.1 217.5 708.0

11.25 kg/cm 2 — 188 °C kg/h 49.1 - -


29.54 kg/cm 2 -346 °C kg/h 37.8 103.4 -
44.29 kg/cm'-402C kg/h 33.6 98.7 321.1
Conditions
- 80 °F ambient temperature - 4 in. H 2 O inlet loss
- Sea level - Natural gas fuel - HHV
- Exhaust losses - 3600 rpm power turbine speed Figure 2. Comparison of LM5000 Gas Generator with CF6-50 Turbofan En-
10 in. H 2 O for unfired boilers - For fired boiler systems gine.
14 in. H 2 O for suppi. fired boilers - suppl. fired at 1400 °F
20 in. H 2 O fo r fu lly fir ed bo i le r s - fully fired to 10% excess air
The three-stage power turbine utilizes the same design concepts em-
ployed in aircraft engines to achieve a high power-to-weight ratio. Airfoil
design of the power turbine, which couples aerodynamically to the gas
Table 3 generator, uses the high-aspect-ratio, tip-shrouded concepts employed for
ESTIMATED HOT SECTION REPAIR INTERVALS
aircraft engine low-pressure turbines to achieve high component
efficiencies in each stage. To meet the design objective for adaptability for
Operating Fuel either 50 or 60 Hz electrical power generation, the aerodynamic design of
Condition Natural Gas Distillate the power turbine is optimized at approximately 3300 rpm. Operation up
Continuous (hl 250 2 00
utylh) 000 1 to 4000 rpm is achievable without changes in airfoil design or rotor mate-
ea rials. Opposite direction rotation is achievable by changing the rotor and
stator airfoils.

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Package Power Plant combustor. The combustion process is initiated by means of one of the
The LM5000 package power plant is a combination of both second- two redundant, electrically activated ignitors. These ignitors are switched
"off" once the combustion process becomes self-sustaining.
generation designs successfully verified by the earlier LM2500 aircraft-
derivative package and the MS series of packaged power plants, combined The hot gases produced by the combustion process are directed into
with some unique requirements for the new turbine. Capability for in- the HPT where they are expanded to produce the mechanical energy re-
module maintenance and quick removal/installation of the gas turbine are quired to drive the high-pressure compressor. The blades and vanes of
unique features to aircraft-derivative designs. Existing proven com- the high pressure turbine are cooled with air extracted from the HPC.
ponents are retained where feasible. For example, the MS6001 load gen- This air is circulated through passages inside the airfoils. Cooling air is
erator is ideally suited for use with the LM5000 since the power range, the discharged through holes in the airfoil walls and mixed with the hot
direction of rotation, and the centerline height are totally compatible with combustion gas as it passes through the HPT.
the direct-drive power turbine (no intermediate gear is required). In addi-
Both the combustor and high pressure turbine are contained within the
tion, the generator uses the same designs as the MS6000 for the static (or
middle support structure of the gas generator known as the compressor
brushless) excitation system and for other generator auxiliaries. The tur-
rear frame.
bine airflow requirements are also similar to those of the MS6001, en-
abling use of many previously proven power systems and components, Upon exiting the high-pressure turbine, the hot gasses are directed
such as the inlet air system. through the aft support structure of the gas generator, termed the turbine
In consideration of maintenance ease and continuous duty operation, midframe, into the low-pressure turbine. Here the gases are expanded
many of the components and systems were strategically located for access across the turbine to drive the low-pressure compressor. From the LPT
outside the turbine compartment. For example, the lube oil tank and the hot combustion gases enter directly into the power turbine where they
filters were placed in a separate accessory compartment at ground level. are expanded further to convert the remaining thermodynamic energy into
mechanical energy to drive an output load device, usually an electrical
Aircraft-derivative turbines require fire-resistant synthetic lube oil generator. After expanding through the power turbine, the exhaust gases
since their rolling element bearings operate at high temperatures. Load are then routed through the power turbine support structure, known as
generators operate with sleeve-type bearings in a more benign local en- the power turbine frame, which also serves as the forward section of the
vironment and use mineral oil. Therefore, a major design consideration exhaust diffuser.
was the use of two separate lube oil systems: synthetic for the gas turbine
and mineral for the load generator. The forward end of the low-pressure spool is supported by means of a
single roller bearing located in the front frame. Two roller bearings in the
EQUIPMENT DESCRIPTION turbine midframe support the aft end of the low-pressure spool. Axial
thrust of the low-pressure spool is carried by means of a ball bearing in
LM5000 Gas Turbine Description
the front frame. Radial support of the high-pressure spool is achieved by
The LM5000 gas turbine is a three-shaft machine consisting of a dual- means of three roller bearings, one each located in the front frame, the
rotor gas generator with an aerodynamically close-coupled, free-power tur- compressor rear frame, and the turbine midframe. Axial thrust loading of
bine (Figure 3). The dual-rotor gas generator consists of an inlet section; the high-pressure spool is carried by means of a single ball bearing in the
a 5-stage axial-flow, low-pressure compressor (LPC); a 14-stage axial-flow, compressor rear frame. The power turbine rotor is supported radially by
variable geometry, high-pressure compressor (HPC), an annular axial means of two roller bearings and axially by means of a ball bearing, all of
swirler combustor; a 2-stage air-cooled, high-pressure turbine (HPT); a which are located in the power turbine frame.
single-stage low-pressure turbine (LPT); and an accessory drive gearbox.
The LPT drives the LPC via a concentric drive shaft forming the low- A radial drive shaft extending through the bottom strut of the front
frame transmits mechanical power from the gas generator high-pressure
pressure spool. The HPC which connects directly to the HPT forms the
high-pressure spool. The portion of the gas generator consisting of the rotor to an accessory gearbox used to drive gas-turbine-mounted acces-
sories such as the fuel pump, the control system hydraulic pump, and the
HPC, the combustion section, and the HPT is termed the high-pressure
lube supply and scavenge pumps for the gas generator and power turbine.
"core." The power turbine consists of a 3-stage turbine with an output
shaft coupling adaptor and a support frame. This mechanical connection between the gearbox and HP rotor also serves
as a means of rotating the gas generator for start-up.
The LM5000 gas turbine uses the same modular design concept as the
CF6 aircraft engine and the LM2500 industrial gas turbine. This design
concept (Figure 4) allows on-site component replacement without remov-
ing the gas generator from the module_

Figure 3. LM5000 Gas Turbine.

Combustion air enters the gas generator through an inlet section con-
sisting of a bellmouth and spinner. The inlet section directs the airflow
into the 5-stage axial-flow, low-pressure compressor which compresses the
air by a ratio of approximately 2.5:1. The air leaving the LPC is directed
into the HPC through the front frame. During low-power operation
modulated bleed doors arranged along the outer flow passage of the front Figure 4. Gas Generator Parts,
frame regulate the airflow into the high-pressure compressor to maintain
the required LPC stall/surge margin.
Power Plant Package
Next, the air enters the HPC where it is compressed by a ratio of ap-
proximately 12:1. Variable pitch inlet guide vanes and five stages of vari- This section describes the major systems and components supporting
able pitch stator vanes maintain the HPC stall/surge margin, by control- the gas turbine operation for industrial use. These major components are
ling airflow and compressor stage loading. The air leaving the IIPC is tested in the factory prior to shipping. Figure 5 is a typical arrangement of
then directed into the annular combustion section, where it mixes with the power plant package showing the relationship and overall dimensions
fuel injected by means of 30 fuel nozzles spaced equally around the of the modular building blocks in the entire system.

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A passageway separates the turbine and accessory compartments. All
I Ill- electrical connections to the accessory and turbine compartments are made

TLiL_ U in this area, with plug-in cabling and removable covers for easy access.
Inlet air system

1
EXHAUST
Gas turbine combustion air is supplied by an inlet system that directs
filtered ambient air through a series of ducts, silencing panels, and screens
iILiER
COMP
K to a plenum enclosing the gas turbine bellmouth. The flowpath is opti-
mized at the bellmouth for minimum distortion and swirl angle.
3 pp Ff
9t5M
An up-and-over configuration similar to those of other proven General
GE
CAB INLET COUP
CON
COUP X
COMP Electric installations was selected as a standard. Figure 6 also shows the
CAB
side and axial options. Since at 275 lb/s (125 kg/s) the LM5000 and
,90f 1 MS6001 airflows are approximately the same, many of the proven system
M27M
GTty5W components and options are the same, including self-cleaning filtration.
Self-cleaning filters also provide an anti-icing capability.
Figure 5. LM5000 Gas Turbine Package Power Plant. Sealing between the turbine bellmouth and aft plenum wall is accom-
plished through a flexible neoprene diaphragm which permits turbine axial
translation (approximately 1.2 in. [3 cm]) due to thermal expansion. A
Turbine compartment drain in the plenum floor collects and removes any liquids accumulated
This major component provides structural support for the gas turbine during waterwash maintenance operations. A hatch on the plenum side
and a suitable enclosure for turbine operation in all ambient conditions panel permits access for any maintenance chores. Junction boxes for all
(Figure 6). The enclosure attenuates turbine noise and, although normal- turbine compartment electrical connections are mounted externally on the
ly ventilated, provides a sealed container for fire protection. The base forward plenum wall.
structure also supports the inlet and exhaust plenums at each end of the Exhaust gas system
compartment. The gas turbine is not installed until the last field opera-
tion. Exhaust gas diffusion and exit design is similar to the LM2500, except
that, in lieu of a piston ring seal, the LM5000 utilizes a flexplate seal be-
tween the outer diffuser wall and the exhaust plenum. As with the
LM2500, a piston ring design is used for the inner wall seal with a one-
piece load coupling guard, thus minimizing exhaust gas leakage. A transi-
tion duct is positioned between the plenum and the ducting/silencing sec-
tion in a vertical exhaust configuration. This entire exhaust system is sup-
LEFT ported from the turbine base and requires no external structure. For heat
recovery applications requiring a side exhaust configuration, an expansion
section is provided between the plenum and transition ducting. Exhaust
thermocouples mounted to the aft plenum wall are available for exhaust
gas temperature reference.
The plenum flooring slopes to a common drain provided for removing
liquids which may accumulate during either waterwash or false starts on
distillate fuel. A drain valve is maintained in a closed position by gas tur-
bine compressor bleed air during operation.
iHT
Load generator

AXIAL By operating with near equal efficiency at 3000 and 3600 rpm, the
LM5000 provides compatibility with either 50 or 60 Hz applications, thus
Figure 6. Inlet Options. permitting the direct drive of the load generator without a reduction gear.
Rotational direction and shaft output of the power turbine permit common
use of the MS6001 load generator. Locating the centerline at 60 in.
An isolated gas fuel control compartment is attached to the side of the (152 cm) above ground level facilitates maintenance and installation of
turbine compartment. An overhead rail system, including a hoist with an the coupling between turbine and generator.
eight-ton (7256 kg) capacity, is permanently installed within the compart-
ment for heavy lifts. Floor grating, level with the base beams, protects The generator tube oil skid contains an oil tank, ac motor-driven
the lower piping/conduit and serves as a permanent workstand for gas tur- pumps with a dc emergency pump backup, and tube oil-to-water heat ex-
bine maintenance tasks such as borescope inspection. A side-mounted changers. The standard excitation system is static bus-fed with a brushless
door permits access to the compartment when the turbine is not running. system available when required.
Internal lights and a window in the door permit visual inspection while the
unit is operating. Silencing

Dual roof-mounted vane-axial fans located at the forward end provide In addition to the acoustic enclosure provided around the gas turbine,
8 ft (2.44 m) of silencing baffles are located in the inlet ducting and 15 ft
compartment ventilation air. This air is channeled under and around the
exhaust plenum before exiting upward via a duct behind the exhaust ple- (4.57 m) in the exhaust ducting to reduce the noise levels. Collectively,
num. Positive pressurization of this compartment allows operation of the these design techniques reduce noise levels to 60 dbA levels far field (at
vane-axial fans in a relatively cool environment. 400 ft [122 m]) and 90 dbA near field (at 3 ft [I m]).

Accessory compartment Installation and removal of the gas turbine


A walk-in accessory compartment containing the gas turbine tube oil Turbine installation or replacement is accomplished within one work-
tank, dual tube oil filters, air-oil separators, dual oil-to-water heat ex- day, and the procedures are identical. First, the gas turbine is shipped in
changers, operator gage panel, water pumps, compressed air subskid for two modules: (I) the gas generator and (2) the power turbine. Each
the self-cleaning air filter, and optional fuel oil control system for dual- or module is shipped in a sealed container designed to withstand shipping
single-fuel operation, is located forward of the turbine compartment. A loads of 3 g's forward/aft, 3 g's vertical, and 1.5 g's lateral. In addition,
water-to-air heat exchanger system is installed in the roof. Electrical junc- the sealed containers also serve as excellent long-term storage packages in
tion boxes located outside the aft rear wall interconnect the other major the possible event of either extended in-transient shipping or on-site con-
assemblies. struction delays. Installation of the gas turbine is preceeded by installation

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L

of the load coupling. Support bars and a hoist in the exhaust plenum pro- 10

vide a temporary support to the forward end of the load coupling.


ISO Conditions
Both the power turbine and gas generator are then installed in the tur-
bine compartment from their respective shipping containers using the
8
internal trolley and hoist. Because of size and weight considerations, the
gas generator and power turbine ate always handled separately. Normal
installation with an adequately trained work force requires about one work
shift. Figure 7 shows the assembled unit within the turbine compartment.
6

H
a 4 i C

Hz

2 1 a

U Ill LU "I 4u
Figure 7. Turbine and Accessory Compartments. SHAFT HORSEPOWER/1000

Figure 9. HC vs. Power.


Control system
The Speedtronic Mark IV turbine control system provides all functions
necessary for operating, monitoring and controlling the gas turbine. Mi-
crocomputer technology provides improved reliability, quality, and moni-
toring capability over traditional solid-state controls. Reliability is im-
proved further by having three identical computers simultaneously moni-
tor and perform control and protection calculations. This redundancy en- 200

ables repair of a malfunctioning computer while the turbine continues to


operate. Quality is improved because wiring and packaging of electronic
equipment is standardized, regardless of application. Site variables are
contained in software. This repeatability facilitates automatic on- and off- 150
line diagnostics to assist hardware testing in both the field and the factory.
Monitoring capability includes access to any control parameter or logic sig-
nal in the control which the CRT can display in engineering units and

o
group with other parameters of the same type. Built-in circuits provide ac- 100
cess to this data at either the local printer or a remote station on demand,
with an RS232 port available. The communicator module may be dupli-
cated up to 4000 ft (1218 m) distance to provide the same complete re-
mote operation displays and alarms as the primary control panel. ISO Conditions
50
Dlesel #2 Fuel
EXHAUST EMISSIONS swmr
0 5% ,

When operated using fuels which meet the specified requirements, the
gas turbine exhaust gases are free of visible smoke and meet federal emis-
0
Sion standards for carbon monoxide (CO), unburnt hydrocarbons (r1C), o ID 20 30 50 20 60
sulfur oxides (SO), and particulates (Figures 8-11). However, like all SHAFT t1ORSEPOWFR/1000
high-pressure-ratio, high-efficiency gas turbines, emission of nitrous ox-
ides (NO,) are greater than those of low-pressure-ratio, low-firing-
Figure 10. SO, vs. Power.
temperature machines (Figure 12). NO, emission can be controlled to re-
quired levels by means of water or steam injection into the combustor.
Figure 13 shows the effectiveness of water injection on NO, T emissions.

150

ISO Conditions

10( H
H H
H a
9N
H.]
a
F
0
5l
H
ISO Conditions
Diesel #2 Fuel
4
10 20 30 40 50 61

SHAFT HORSEPOWER/1000

+V YVSHAFT HORSEPOWER/1000 =V VV VV

Figure 8.
Figure CO vs. Power. 11. Particulates vs. Power.

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bine components manufactured using production tooling was conducted in
1983 and early 1984. Instrumented load testing of the first production
power turbine was completed in the third quarter of 1984 (see "Power
Turbine Testing").
Power Plant Packaging
Initiated in 1981, the power plant package design was completed in
1983. A fitup test of the gas turbine and package components was per-
formed in the fourth quarter of 1984.
Site Tests
The remaining tasks conducted at the field site include installation and
M functional checkout of the entire station. Special control evaluation tests,
compartment cooling effectiveness, and unit performance measurements
will conclude the design tasks remaining for this program.
DEVELOPMENT TESTING
kru
Gas Generator
UP5
^^y Initial development testing of the LM5000 gas generator was complet-
e^ ed in 1977. Testing was conducted on the first production gas generator
which was instrumented to evaluate the mechanical design of the unique

//
LPC and LPT components, the lubrication and sump pressurization sys-
tem operation, the variable geometry control system operation, and gas
ISO Conditions generator performance characteristics. These tests included:
IM • Incremental power surveys for mechanical design verification
• LP compressor and turbine mapping
• Transient operation tests
• Unbalanced rotor tests

• Emissions testing
10 20 30 40 50 60
• Overspeed tests
SHAFT HORSEPOWER/1000
• Performance verification tests
Figure 12. NO, vs. Power. Since 1978 additional engineering tests have been conducted on the gas
generator to refine the design for industrial applications. In conjunction
with over 46 000 h of commercial operation, tests were conducted both in
500
the factory and under actual field conditions. Tests to develop dual fuel
N.^ecli^u,
capability, combustor water injection for NO 3 control, and development of
improved sensors for increased control system reliability were included.

400
Power Turbine Testing
Engineering tests to evaluate various design parameters of the power
turbine were accomplished by means of an instrumented load test of the
0 first production turbine. The power turbine components were instrument-
300 ed with strain gages and thermocouples for mechanical design evaluation:
temperature and pressure sensors for evaluation of sump pressurization
8 and lubrication systems as well as for thermodynamic performance. Power
turbine testing was accomplished by assembling the turbine with a
200 Fr
LM5000 gas generator and absorbing the output shaft load via water brake
z dynamometers. The tests included were:
• Incremental load survey for mechanical design verification.
• Transient operation
100 gas • Turbine performance mapping
• Unbalance rotor tests
• Emergency shutdown demonstration
• Overspeed demonstration
0 The results of these power turbine tests showed the turbine airfoils and
10 20 30 40 50 60
mechanical structure to be free of any detrimental resonances in the oper-
WATER FLOW. GPM ating range. Turbine sensitivity to unbalance conditions was much less
than expected with a measured deflection of only 2 mil (.05 mm) with
1300 g-in. (3302 g-cm) of unbalance. The thermodynamic performance
0 s 1.0 1.5
of the turbine exceeded the design predictions, thus ensuring that the
WATER TO FUEL WEIGHT RATIO overall gas turbine simple-cycle thermal efficiency will exceed 37.5% at
rated conditions for 60 Hz electrical power generation applications.
Figure 13. Water-to-Fuel Weight Ratio.
Component and Subsystem Test
Most of the systems and subsystems are adaptions using existing power
DEVELOPMENT PROGRAM equipment with minor modifications for this specific size aircraft-
derivative gas turbine. Component and subsystem design verification test-
Gas Turbine ing was required in these areas:
The LM5000 gas generator was designed and developed in the mid • Turbine control
1970s, with the first production unit delivered in 1978. Based on a busi- • Turbine air inlet flow
ness decision to proceed with the total gas turbine system design, a major • Lube oil pump
effort was initiated in June 1981 to design and build a power turbine. The • Fuel pump clutch
power turbine design was completed in mid 1982. Testing of the first tur- • Gas turbine interchangeability

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A series of flow tests using 1/4 scale models of the plenum; the transi- SUMMARY
tion duct; and the gas turbine bellmouth, spinner, and compressor walls This paper describes a new aircraft-derivative package power plant de-
was conducted to develop an inlet design which achieved the established veloped for cogeneration and electrical utility applications. A description
inlet flow conditions within 5 steady-state and 10 dynamic angular devia-
0
0
of the major subsystems and packaging designs is included for the com-
tion from axial flow. Testing was conducted in General Electric's Gas plete power plant. The LM5000 gas turbine is the latest land-use design
Turbine Laboratory, Schenectady, New York, using the standard up-and- derived from the highly reliable CF6-50 flight engine in the 50 000 hp
over inlet system configuration upstream of the inlet plenum. Pressure class. Simple-cycle effeciency in excess of 37.5% has been demonstrated.
probes located downstream of the bellmouth in the gas path measured Power turbine efficiency, as measured during instrumented load tests, ex-
steady-state and dynamic swirl angles at eight equal spaced sectors at the ceeded design expectations. The first LM5000 package power plant is be-
face of the compressor. ing prepared for field test and evaluation in 1985.

The final inlet plenum configuration, selected on the basis of compli- REFERENCES
ance to the inlet air swirl requirements, incorporates a screen at the ple- 1. R.D. Repass, G.A. Hardgrove, and J.C. Rucigay, "GE LM5000
num entrance plus flow splitters at three locations on the aft plenum wall Aircraft-Derivative Gas Turbine System," General Electric Gas Tur-
adjacent to the gas turbine bellmouth. bine Reference Library, October 1983, GER-3425.
2. General Electric Co., "LM5000 Gas Turbine Exhaust Emissions,"
Qualification testing of two gas-turbine-mounted accessories, a power Report MID-TD-5000-6, July 1983.
turbine tube oil pump, and a fuel pump clutch was conducted. Both tests 3. J.M. Kovacik, "Cogeneration Application Considerations," presented
were accelerated cyclic endurance bench tests. Initial testing produced a at the General Electric Turbine Technology Seminar to Industry, Lon-
failure of the positive displacement vane pump: Cracks were observed in don, England, October 1983, GER-3430.
the pumping element vane of both the supply and scavenge elements. 4. J.A. Jackson, "Aircraft-Derivative Practices," presented at the Gen-
Both areas were redesigned and the pump retested. The cyclic test pro- eral Electric State-of-the Art Seminar to Industry, September 1984,
gram of the fuel pump clutch is currently in progress. GER-3424.

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