GE FRAME 6B,9E & 9FA

GAS TURBINES

Principle of working:- Works on Braton
Cycle with two nos. Adiabatic
processes of compression & expansion
in compressor and turbine respectively
and two constant pressure processes
i.e. Heat addition in combustion
chambers and exhaust in atmosphere.

BRATON
CYCLE
The Actual Thermodynamic
cycle

For all practical reasons the
actual thermal efficiency
will depend on

Pressure ratio
Turbine inlet Temp
Compressor inlet temp
Efficiency of Compressor and
Turbine
Principle of Operation:- Rotor is initially
brought to speed by starting means.
Atmospheric air is drawn into the compressor
and raised to static pressure more than the
atmospheric. This high pressure air is
allowed to pass through continuous flow
Combustion Chambers where fuel is ignited
with high voltage igniters. The product of
combustion is expanded in the turbine which
cause it to spin and thus applying a torque to
the driven accessories i.e. Generator

WORKING PRINCIPLE


Time
1
2
3
4
0
0-1 Cranking
1-2 Purging
2-3 Speed down to firing speed
3- Firing
3-4 Warm up
4-5 Acceleration
5-6 Full Speed no load
5
6
Torque converter angle
Fuel
Speed
THE MAIN & MOST IMPORTANT
CONCERNS OF THE GT UTILITIES
ARE

LOW MAINTENANCE COST
HIGH AVAILABILITY


TO KEEP LOW COST OF OPERATION
& HIGH AVAILABILITY OF M/Cs, A
WELL PLANNED MTC. PROGRAMME
IS REQUIRED
TYPE OF FUEL USED
FIRING TEMPERATURE
OVERSPEED OPERATION OF M/C
DESIGN FEATURES
DUTY CYCLE
PARTS AVAILABILITY
ON SITE MTC. CAPABILITY
DIAGNOSTIC & EXPERT SYSTEM OF
ANALYSIS
MFRS RECOMMENDED MTC. PROGRAM
MTC. PLANNING IS AFFECTED BY
NATURE OF OPERATION PHILOSOPHY I.E.
PEAKING OR BASE LOAD OPERATIONS,
STANDBY OPERATION & NO. OF STARTS
& SHUTDOWNS.
GAS TURBINE WEARS IN DIFFERENT
WAYS FOR DIFFERENT SERVICE
REQUIREMENTS AND DUTY CYCLES.
THERMAL MECHANICAL FATIGUE IS THE
LIMITER FOR CYCLIC OPERATION AND
CREEP, OXIDATION, HOT CORROSION ARE
THE LIMITER FOR CONTINUOUS DUTY
APPLICATIONS


EFFECTS
TMF
HCF
RUB/ WEAR
FOD


EFFECTS
CREEP
RUPTURE
HCF
CORROSION
OXIDATION
EROSION
RUB/WEAR
FOD


OPERATING DUTY DEFINITION
Fired
Duty Service Factor Hrs/Starts
Stand-by <1 % 1 to 4
Peaking 1% to 17% 3 to 10
Cycling 17% to 50 % 10 to 50
Continuous >90 % >>50

FIRING TEMP. IS THE LIMITING FACTOR
FOR LOAD ON THE TURBINE. HIGHER THE
FIRING TEMP. SHORTER WILL BE THE
MTBI. HIGH FIRING TEMP. MAY BE DUE
TO-
PEAK LOAD OPERATION OF M/C
WET CONTROL CURVE OPERATION OF M/C
WITH STEAM/WATER INJECTION OR WITH
INLET FOGGING
PART LOAD OPERATION OF M/C IN
COMBINED CYCLE

WITH USE OF HEAVY FUELS IN GTs, THE
MTC. INTERVALS ARE REDUCED AS DUE
TO BURNING OF HEAVY FUELS RADIANT
THERMAL ENERGY IS RELEASED
RESULTING INTO REDUCTION OF HGP
SPARES LIFE. ALSO PRESENCE OF
CORROSIVE ELEMENTS IN THE HEAVY
FUELS HOT CORROSION IN HGP SPARES
IS INCREASED.
CONTD.
FUEL USED IN GAS TURBINE IS THE KEY
FACTOR IN DECIDING THE MTC.
PLANNING. THE SEVERITY FACTOR FOR
VARIOUS FUELS ARE AS FOLLOW -
GAS - 1
DISTILLATE - 1.5
CRUDE - 2 TO 3
RESIDUAL - 3 TO 4

GAS TURBINE OPERATION ON GAS
FUEL FOR CONTINUOUS DUTY CYCLE
WITH NO STEAM/ WATER INJECTION IS
CALLED BASE LINE OPERATION .

IN BASE LINE OPERATION MTC.
INTERVAL BETWEEN TWO INSPECTIONS
IS THE MAXIMUM AS THE MTC. FACTOR
IS UNITY.

MTC. FCATOR FOR OVER SPEED
OPERATION OF MACHINE-


%
SPD
100 101 102 103 104 105
MF 1 1.2 1.4 1.6 1.8 2

ALL THE CASINGS STARTING FROM INLET
PLENUM TO EXHAUST CASING ARE SPLIT
AT HORIZONTAL CENTRE LINE TO
ACCESS INTERNALS FOR INSPECTION
/REPLACEMENT. BRGS., IGV, COMP.
STATOR BLADES, NOZZLES, SHROUDS
ETC, CAN BE REPLACED WITHOUT
ACTUALLY LIFTING THE TURBINE ROTOR

AS PER GE FOLLOWING PREVENTIVE MTC.
INSPECTIONS ARE CARRIED OUT ON GTs

BOROSCOPIC INSPECTION
COMBUSTION INSPECTION (CI)
HOT GAS PATH INSPECTION (HGPI)
MAJOR INSPECTION (MI)

DURING CI, FUEL NOZZLES AND
COMBUSTION CHAMBERS OF GAS
TURBINE ARE DISASSEMBLED FOR
INSPECTION AND BOROSCOPIC
INSPECTION IS CARRIED OUT FOR
COMPRESSOR AND TURBINE
PORTION
CONTD....

DURING CI FOLLOWING SPARES ARE
INSPECTED/ REPLACED
FUEL NOZZLES
COMBUSTION LINERS
TRANSITION PIECES
X. FIRE TUBES
RETAINERS
END SEAL BLOCKS
BULL HORN
END SEALS




RECOMMENDED INTERVAL FOR CI IS
AS GIVEN BELOW-
TYPE OF
INSP
RECOMMENDED HRS/STARTS

6B 9E 9FA

CI
DLN

12000/450 12000/450 8000/450
NON
DLN
12000/1200

8000/900 -
CALCULATION FOR MTC. INTERVAL FOR CI BASED ON
HRS CRITERION -

MTC. INTERVALS (HRS)= RECOMMENDED HRS
MTC. FACTOR
MTC. FACTOR = ANNUAL FACTORED HRS
ANNUAL ACTUAL HRS

ANNUAL FACTORED HRS = G+ 1.5D + 3H + 6P
ANNUAL ACTUAL HRS = G + D + H + P

G = ANNUAL HRS OF OPR. ON GAS FUEL
D = ANNUAL HRS OF OPR. ON DISTILLATE FUEL
H = ANNUAL HRS OF OPR. ON HEAVY FUEL
P = ANNUAL HRS OF OPR. ON PEAL LOAD


DURING HGPI, FUEL NOZZLES,
COMBUSTION CHAMBERS AND
TURBINE PORTION OF GAS
TURBINE ARE DISASSEMBLED FOR
INSPECTION AND BOROSCOPIC
INSPECTION IS CARRIED OUT FOR
COMPRESSOR PORTION
CONTD....

DURING HGPI FOLLOWING SPARES ARE
INSPECTED/ REPLACED

ALL THE SPARES OF CI +
BUCKETS STG .I, II & III
SHROUD STG .I, II & III
NOZZLE STG .I, II & III
VIGV & EXHAUST FRAME
BOROSCOPE INSPECTION OF COMPRESSOR



HOT GAS PATH INSPECTION
RECOMMENDED INTERVAL FOR HGPI
IS AS GIVEN BELOW-
TYPE OF INSP RECOMMENDED HRS/STARTS

6B 9E 9FA
HGPI

24000/1200 24000/900 24000/900
CALCULATION FOR MTC. INTERVAL FOR HGPI BAESD
ON HRS CRITERION -

MTC. INTERVALS (HRS)= 24000
MTC. FACTOR
MTC. FACTOR = ANNUAL FACTORED HRS
ANNUAL ACTUAL HRS

ANNUAL FACTORED HRS = G+ 1.5D + 3H + 6P
ANNUAL ACTUAL HRS = G + D + H + P

G = ANNUAL HRS OF OPR. ON GAS FUEL
D = ANNUAL HRS OF OPR. ON DISTILLATE FUEL
H = ANNUAL HRS OF OPR. ON HEAVY FUEL
P = ANNUAL HRS OF OPR. ON PEAL LOAD
HOT GAS PATH INSPECTION

DURING MAJOR INSPECTION,
FLANGE TO FLANGE OF GT IS
DISASSEMBLED/INSPECTED. IT
INCLUDES F/N, CC, TURBINE,
COMPRESSOR & BEARINGS. OTHER
AUXILIARIES AND SUPPORT SYTEM
I.E. INLET PLENUM, EXHAUST
PLENUM, OIL PUMPS, AGB ETC ARE
INSPECTED.
CONTD....

DURING MAJOR INSPECTION FOLLOWING
VITAL SPARES ARE INSPECTED/
REPLACED

ALL THE SPARES OF HGPI +
VIGV, INLET PLENUM & EXHAUST PLENUM
COMPRESSOR
TURBINE BEARINGS
AGB, MOP, AOP, EOP, ATOM. AIR COMP.
STARTING MEANS, STARTING CLUTCH
ATOM. AIR COOLER & L.O. COOLER



RECOMMENDED INTERVAL FOR MI IS
AS GIVEN BELOW-
TYPE OF
INSP
RECOMMENDED HRS/STARTS

6B 9E 9FA
MAJOR
INSP.

48,000/2,400 48,000/2,400

48,000/2,400

CALCULATION FOR MTC. INTERVAL FOR MAJOR
IISPECTION BAESD ON HRS CRITERION -

MTC. INTERVALS (HRS)= 48,000
MTC. FACTOR
MTC. FACTOR = ANNUAL FACTORED HRS
ANNUAL ACTUAL HRS

ANNUAL FACTORED HRS = G+ 1.5D + 3H + 6P
ANNUAL ACTUAL HRS = G + D + H + P

G = ANNUAL HRS OF OPR. ON GAS FUEL
D = ANNUAL HRS OF OPR. ON DISTILLATE FUEL
H = ANNUAL HRS OF OPR. ON HEAVY FUEL
P = ANNUAL HRS OF OPR. ON PEAL LOAD

LOAD Vs EXHAUST TEMPERATURE
VIBRATION LEVEL
FUEL FLOW AND ITS PRESSURE
EXHAUST TEMPERATURE & SPREAD VARIATION
START UP TIME
COASTING DOWN TIME
WHEEL SPACE TEMPERATURE
CPD & CTD
INLET AIR DIFF. PRESSURE ACROSS FILTERS
EXHAUST PRESSURE DROP

PERFORMANCE INDICATORS
INLET AIR DIFF. PRESSURE
EXHAUST GASES DIFF. PRESSURE
AMBIENT AIR TEMPERATURE
GENERATING FREQUENCE
STEAM / WATER INJECTION
INLET AIR FOGGING
TYPE OF FUEL USED


EFFECT OF DIFF. FACTORS ON
GT PERFORMANCE/ OUTPUT
INLET AIR & EXH. DIFF. PRESSURE
(FRAME 9E)










VALUE F/CONSMP OUTPUT
INLET PR
DROP
100 mm of
H2O

+ 0.4 -1.4
EXH. PR
DROP
100 mm of
H2O
+ 0.4 - 0.4
EFFECT OF INLET AIR TEMP. ON
GT PERFORMANCE/ OUTPUT
MODEL PG 9001E
INLET
TEMP
(F)
EXH.
TEMP
(F)
HEAT
RATE
(%)
OUTPUT
(%)

HEAT
CONSMP.
(%)
AIR
FLOW
(%)
20 929 97 116 112 108.5
40 939 98.5 108 106 104
60 952 100 100 100 100
80 964 102.5 94 94 95.5
100 978 105 84 88 91.5
120 993 108 77 83 87.5
MODEL PG9001E

EFFECT OF FREQUENCY ON
GT PERFORMANCE/ OUTPUT
FREQUENCY
(Hz)
OUTPUT
(%)
50.0 100
49.5 100
49.0 99
48.5 98
48.0 97
47.5 96
47.0 95
LIFE EXPECTANCY OF GT ROTOR
HRS. BASED GT ROTOR LIFE CALCULATION

ROTOR MAINTENANCE INTERVALS = 144000 HRS.
MF

MF = H + 2P + 2 TG
H + P

H = BASED LOAD HRS
P = PEAK LOAD HRS
TG = HRS ON TURNING GEAR
LIFE OF HGP SPARES
MODEL 9E
REPAIR REPLACEMENT
F/NOZZLES CI 2 (CI)/3 (CI)
COMBUSTION LINERS CI 3 (CI)/5 (CI)
TRANSITION PIECES CI 4 (CI)/6 (CI)
X- FIRE TUBES CI 2 (CI)/3 (CI)
BUCKETS STG. I, II & III HGPI 2(HGPI)/3(HGPI)
NOZZLES STG. I, II & III HGPI 3(HGPI)/3(HGPI)
SHROUDS STG. I, II & III HGPI 3(HGPI)/3(HGPI)
Probability of not being forced out of
service when unit is needed

RELIABILITY = (1- FOH /PH)X100

FOH Forced Outage Hrs.
PH Period Hrs.
Probability of being available,
independent of whether the unit is
needed.

AVAILABILITY = (1- UH /PH)X100

UH Unavailable Hrs.
PH Period Hrs.

Probability of a combined cycle power
plant not being totally forced out of
service when unit is required includes
the effect of Gas & Steam cycle MW
output contribution to plant output.

= [1-{GTFOH +B( HRSGFOH +STFOH)}X100]
GTPH BPH STPH
contd.
EQUIVALENT RELIABILITY
GTFOH = GT Forced Outage Hrs.

GTPH = GT Period Hrs.

HRSGFOH = HRSG Forced Outage Hrs.

BPH = HRSG Period Hrs.

STFOH = Steam Turbine Forced Outage Hrs.

STPH = Steam Turbine Period Hrs.

B = Steam Cycle MW output contribution
EQUIVALENT AVAILABILITY
Probability of a combined cycle power
plant available for power generation
independent of whether the unit is
needed -includes the effect of Gas &
Steam cycle MW output contribution to
plant output.
= [1-{GTUH +B( HRSGUH +STUH)}X100]
GTPH BPH STPH
contd.

EQUIVALENT AVAILABILITY
GTUH = GT Unavailable Hrs.

GTPH = GT Period Hrs.

HRSGUH = HRSG Unavailable Hrs.

BPH = HRSG Period Hrs.

STUH = Steam Turbine Unavailable Hrs.

STPH = Steam Turbine Period Hrs.

B = Steam Cycle MW output contribution
MTBF Measure of probability of
completing the current run. Failure
events are restricted to forced outages
while in service.
MTBF= SH/FO

SH Service Hrs.
FO Nos. of Forced Outages
Service Factor Measure of
operational use usually expressed on
an annual basis.

Service Factor = SH/PH X 100

SH Service Hrs.
PH Period Hrs.

OPERATING LEVERAGE

OPERATING LEVERAGE = FIXED COST
VARIABLE COST

OPERATING LEVERAGE IS GETTING
REDUCED AS THE PLANT GOES OLDER
DUE TO REDUCTION OF FIXED COST BY
WAY OF DEPRECIATION AND INCREASE
IN HEAT RATE DUE TO AGING

CONTRIBUTION FACTOR

C. FACTOR= TARIFF/KWH
VARIABLE COST/KWH

GIVE DC TO SLDC IN SUCH A WAY THAT
THE CONTRIBUTION FACTOR SHOULD
ALWAYS REMAIN POSITIVE TO AVOID
LOSSES. THIS CAN BE DONE BY LOADING
THE MACHINES OPTIMALLY AND
AVOIDING THE PARTIAL LOADING OF
MACHINES FOR LONGER DURATION.
HEAT RATE W.R.T.
LOADING
OUT PUT
(%)
HR
(1
0
C)
HR
(15
0
C)
HR
(32
0
C)
HR
(49
0
C)
120 97 99 101 103
100 99 100 102 103
80 105 106 106 107
60 115 115 115 115
40 133 133 133 133
Performance characteristics for
Frame 6 Gas Turbine at base load
Inlet temp
(C)
Ex.
Temp(C)
HR (%) HC (%) Output (%) Flow (%)
49 567 108 83 77 87
38 561 105 88 84 91
27 556 102 94 92 95
15 549 100 100 100 100
4.5 543 98 105 107 104
-6.6 537 97 112 115 109

Model ISO Rating (kw) ISO Efficiency (%)
(1) MS1002 5070 24.5
(2) MS3142(J) 10450 25.6
(3) PG5371(PA) 26300 28.5
(4) PG6581(B) 42100 32.0
(5) PG6111(FA) 75900 35.0
(6) PG9171(E) 123400 33.8
(7) PG9231(EC) 169200 34.9
(8) PG9351(FA) 255600 36.5
(9) PG9551(H) 380,000 -
Note: ISO output is : 15 deg C, 60% RH, Zero MSL, Gas fuel
and standard Inlet/Exh. Pr. drops
GE FRAME OTHER GT MODELS
OEM Conventional Advance (F/FA class)
Model GT ISO
Output
(MW)
Net CC
Efficiency
(%)
Model GT ISO
Output
(MW)
Net CC
Efficiency
(%)
GE 9E 126.10 52.7 9FA 255.6 57.1
Siemens V94.2 159.40 52.2 V94.3
A
265.9 57.3
MHI* 701DA 144.09 51.6 701F 270.3 57.0
Alstom 13E2 165.10 52.9 GT 26 263.0 56.3
FLANGE TO FLANGE VIEW OF
F CLASS GAS TURBINE


QUESTIONS ?
K. S. YADAV
Manager (M-I)
Pragati Power Station
Cell - 9717694741
email ksyadavipgcl@yahoo.co.in