BHEL Heavy Duty

Gas Turbines
- Recent Developments

Recent developments

Up-rated Models

New Models
Large Advance class Gas Turbines
Areas of Improved design
Advanced materials and coatings
IGCC

Uprated Versions

Fr-6B
Fr-9E
Fr-6FAe+

PG6581B
PG9171E
PG6111FA

New Models

Fr-6C
Fr-9FA
Fr-9FB

PG6591C
PG9351FA
PG9371FB

PG6581 B Improvements

Increased Shaft speed 5163

Increased firing temperature
1140 deg C
Improved turbine sealing
Reduced compressor leakage
Brush seal
13th stage air for cooling Stage 2
Nozzle
Improved N#1,B#1
High performance exhaust
diffuser
Split Accessory Base

PG6561 PG6581
Output, kw

39620

42100

SC Heat Rate, kcal/kwhr 2700

2680

Exhaust Flow, tons/hr

519

530

Exhaust Temp, deg C

532

548

ISO,Base,Gas

PG6581B Stage 1 Nozzle

Enhanced cooling of

platforms and aerofoils.

Improved leakage control
chordal hinge and
additional spline seal.

PG6581B Stage 1 Bucket

New Bucket profile
Optimized cooling

configuration
Existing GTD111DS
material and coating
technology

PG6581B Stage 1 Shroud

Redesigned internal

cooling system
Improved leakage control
HR 120 material
Circumferential
braided seal location

Impingement Sleeve

PG6581B Stage 2 Nozzle

Optimization of cooling

( 13 stage bleed air).

Existing material and
coating technology.

PG6581B Stage 2 Bucket

Enhanced cooling of airfoil.
Contoured tip shroud for

creep life improvement.

Nickel Base alloy material.

PG6581B Exhaust Diffuser

Improved performance
Minimum design changes
Enlarged exhaust plenum
bottom and extensions
Enlarged internal diffuser
profile ring extension

PG9171E Latest Evolution

PG9171E

PG9171E+

Output, kw

123400

126100

Heat Rate, kcal/kwhr

2545

2545

Exhaust Temp, deg C

544

543

Exhaust Flow, tons/hr 1502

1505

PG9171E Latest improvement

Turbine Sealing

improvement
Improved First stage
shroud
One piece design, HR120
material with cloth spline
seal

PG9171E Latest Improvements

Improved 2nd Stage

Shroud Sealing
Non pressurized
diaphragm
Brush Seal

PG9171E Latest Improvements

High performance exhaust
diffuser.

PG6111FA Key features

Increased Firing

temperature
Increased air flow
Higher pressure ratio
Robust rotor design,
No startup dwell time

PG6111FA - Performance

Advance Class Technology

Quantum jump in firing temperatures

Higher efficiencies ( Simple & CC )
More power from single units
Superior metallurgy
Novel Cooling techniques
Novel sealing methods
Improved emissions
Better topping machines for a combined cycle

Advance Class Technology

E-

Firing temperature C

1124

1400

~ 1450

Exhaust temperature C

543

610

NA

Combined cycle eff. %

52

58

60

Power ( GT) MW ( Fr-9)

126.1

279

~300

HGP Cooling

Air

Air

Steam

Blade Casting

DS

SC

Simple cycle eff %

33.7

38

Nox ppm

42/25

F-

25/15

H-

SC
NA
25/15

FA Technology Provides Both Increased

Output and Increased Efficiency

Combined Cycle Plants With Two Gas Turbines

Heat Rate (BTU/kW-hr)

8000
6B
7EA

E Technology

9E

7000
6FA

F Technology

7FA
9FA

6000
0

100

200

300

400

Rating MW

500

600

700

800

Gas Turbines : New Models

PG6591C

Flow back of F Technology into mid range Gas turbines

Evolutionary design based on proven technologies
Built on 6Bs track record
Flow down of F technology

Advanced class GAS TURBINE in the 40 MW

range.

Comparision of 6B vs 6C

6B
18 Stage compressor
IGV
10 combustion
chambers
Std/DLN1 Combustor
3 Stage turbine

6C
12 Stage compressor
IGV and 2 variable
stator blades
6 combustion chambers
DLN 2 Combustor
3 Stage turbine

030

Comparision of 6B vs 6C

Model

Fr-6B

Fr-6C

PG6581B

PG6591C

ISO Rating

MW

41.7

45.4

Heat Rate

Kcal/kwhr

2695

2348

Air Flow

kg/sec

143

122

12.2

19.6

Pressure ratio
Firing Temp.

1140

1327

Exhaust Temp.

547

581

GT Speed

rpm

5163

7100

030

Comparision of 6B vs 6C Key Benefits

Improved operability
Fast and reliable start
Nox turn down to less than 50 %
Improved performance
5% improvement in efficiency over 6B
7.5 % improvement in output over 6B
3 stages of guide vanes for higher part load

efficiency
Low NOx emissions 15 ppm NOx and 9 ppm CO
Layout
Axial exhaust
F class modular arrangement of skids

All compressor blades are field replaceable

without rotor removal

030

Gas Turbines : New Models

PG9351FA
Description

Fr 9FA

ISO Rating

255600 MW

Heat Rate

2332 Kcal/KWH

Simple Cycle Efficiency

36.9 %

Combined Cycle Efficiency

up to 56.2%

Air Flow

647 kg s/sec

Firing Temp.

1327 c

Exhaust Temp.

602 c

Pr. Ratio

16.5

RPM

3000

Overall Wt.(Turbine Base

280 T

Overall Dimensions( Turbine )

11.0 x 5.0m x 5.0m

Rotor Wt/Length

77T / 10.0 m

030

Gas Turbines : New Models

PG9371FB
Fr-9FB : PG9371FB

Gas Turbines : New Models

PG9371FB
Fr-9FB : PG9371FB

Plant Layout

030

Sealing Technology
Better sealing technology through use of

Honey comb seals.

Brush seals.
Cloth seals.
Abraidable coating seals.

The Labyrinth Seal

Stationary Part

Rotating Part

Sealing Locations

At present in F machines
Further advancement

Honey Comb Seal

Honey comb seals inserted

between labyrinth seal teeth
Honey comb seal material softer
than bucket and shroud
Cutter tooth on bucket tip
0.6 % improvement in output
and heat rate

Brush Seal

Brush seal on Nozzle

Typical Brush Seal element

Shroud Cloth Seals

Both radial & axial sealing.

Flexible,allows shroud block
misalignment.
Performance improvement of
up to 0.7 % in output and 0.5 %
in heat rate.

Abraidable coating on shroud

40 mil thick coating on the 1st
stage shroud block.
Bucket tips rub into the coating
and form gas path.
Misalignment of components
automatically taken care of.
Reduced air leakage leads to
0.4 % improvement in output &
heat rate.

Combination of cloth seal on shroud blocks and abraidable coating

provides about 1.1 % increase in power and 0.8 % in heat rate.

Cooling Technology

Better cooling technique.

Reduced cooling air requirement due to better materials. More
air available for power generation.
Serpentine cooling path in 1st stage buckets.
Radial cooling holes in 2nd stage buckets.
Film cooling in Nozzles. Hollow Nozzles.
Impingement cooling of Transition piece.

Cooling air circuit

Last stage wheel with cooling air

extraction

Internal cooling air circuit

Cooling Passages

First stage nozzle segments with cooling

holes
First stage bucket cooling passages

First stage bucket cooling passages

Impingement cooling of Transition piece

Transition piece in two pieces.
Inner transition piece is
surrounded by slotted sleeve.
Air jets impinge on the inner
transition piece

Transition piece

Improved material
Hayes HR120 ( Ni-Cr alloy)
replaces 310SS
Single piece design
Reduced cooling air
requirement

Equiaxed Vs DS
Directionally solidified 1st stage buckets for better creep rupture strength
and fatigue life

Firing temperature trend and Bucket material capability

IGCC
Fuels
Bitum. Coal

Gassification

Lignite

Gasifier

Orimulsion
Residual oils

HX

Cleanup
Products

Pet coke
Bio Mass
Wastes

Oxyg.
System

Combined
Cycle
Hydrogen

2 Stage combustion

Ammonia

Partial in Gassifier

Methnol

Complete in GT

Sulfur

Electricity

IGCC
Coal Gas 16%
Nat Gas 2%
Air
100%

NG Exhaust 102%
C.G Exhaust 116%

Low LCV Gas

Flat rated region

Output
20% Extra Output
Nat. Gas
Typically
14 % extra flow at same firing
Temp makes 28% more power

15 C

Ambient Temp

Thank You