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01/05/2011
Randy Morrell, Laurent Cornu, Jeffrey Goldmeer, GE, USA
Figure 2: Fleet statistics for GEs F-class heavy duty gas turbine fleet
Turbine features
Many of the components in the 9F turbine platform have been developed to provide extra power, higher
efficiency, reduced emissions and increased turndown, as well as increased availability and reliability (see
Figure 3). Enhancements to the compressor system are aimed at increasing durability and availability, while
maintaining or increasing reliability, a vital consideration for plant operators. GE claims that enhancements to
the inlet guide vanes, the forward and mid-stage rotating blades, the forward stage rotor vanes, and the aft stage
vanes dramatically reduce the degradation of and stresses placed on wear-related components. Meanwhile,
advanced material treatments combine to lengthen the compressors effective lifecycle.
These reduced wear characteristics and greater tolerance to normal operating stresses translate
into a robust compressor that is much more tolerant to a wider range of real world operating
environments, reducing the likelihood of service interruptions due to unplanned maintenance
outages. The overall result is a more reliable gas turbine that is available more often. This also
translates into longer intervals between inspections and lower maintenance costs. Specifically, GE
claims the enhanced compressor will increase the average lifetime availability of its 9F gas
turbine by almost 1.9 per cent.
This improved compressor is fitted to all of GEs new 9F gas turbines. It is also available as an
upgrade for the currently installed fleet, with pre-scoped packages on offer to complement
standard planned maintenance outages. These packages range from a control curve change,
requiring only a single day to implement, to full replacement requiring a major inspection. Each
field package removes applicable technical information letters (TILs) and periodic maintenance
requirements, thus increasing the availability entitlement of the gas turbine. Field retrofit outages
have already been completed on some 9FA and 9FB gas turbines, with many more under way and
scheduled. GE has also developed special tools for these procedures to further minimize outage
durations and the impact on operational schedules.
The blade health monitoring system was developed to monitor the R0, R1 and R2 compressor
blades by providing real-time measurements of key static and dynamic deflection features.
Specifically, this system uses a set of non-contacting probes that are placed on the compressor
casing, allowing for data to be collected on the blades passing frequency and amplitude signals.
These probes are connected to an on-site data acquisition system, which in turn connects to an
off-site analysis system. Once collected, this data is compared with GEs proprietary models. This
allows the data to be used, for example, to examine blade trends over multiple starts, and to
analyze static deflection at full-speed and full-load to measure deterioration in the blades, timerelated trends and significant shifts. Since February 2010, this system has been installed on more
than 18 units.
The dry low NOx (DLN) 2.6+ combustor combines the technological advantages of the 9FA gas
turbine DLN2+ combustion system with the 7FA gas turbine DLN2.6 combustion system, as well
as the 9H gas turbine and 6C gas turbine DLN2.5H systems. The DLN2.6+ has the same
configuration as the DLN2.6: five outer fuel nozzles and a single central nozzle. The centre fuel
nozzle ensures a stable combustion across a wide range of operating conditions. To the DLN2.6
system architecture, the DLN 2.6+ adds an advanced fuel nozzle, called the swozzle, from the
DLN2+ and DLN2.5H combustion systems. The swozzle combines the fuel injection gas ports
into the swirler vanes, all within the fuel nozzle body, to provide a better mixed, more stable
combustion zone. A patented asymmetric fuel strategy allows the DLN2.6+ to maintain low
emissions levels while extending the available operational load range. Further advanced
materials, coatings and cooling technology extend the combustion interval beyond the standard
8000 hours of operation.
Specifically, on the 9FA gas turbine, the DLN2.6+ combustion system offers NOx and CO
emissions of 20 mg/Nm3 (9.7/16.2 ppm) to 50 per cent load. With the use of OpFlex Extended
Turndown software, NOx and CO emissions are rated at 30 mg/Nm3 (15/24.3 ppm) down to 35
per cent load with a 24 000 hour combustion interval. On the 9FB gas turbine, NOx and CO
emissions of 30/12.5 mg/Nm3 (9.7/10.1 ppm) are possible down to 38 per cent load with a 12 000
hour combustion interval. This combustor was launched on the 9FA gas turbine in 2005, on the
9FB gas turbine in 2007, and as of July 2010 is in operation in more than 45 gas turbines with a
combined service of more than 340 000 fired hours, and more than 5000 starts. These units are
shown operating in peaking duty, cycling duty and base load as shown in Figure 4.
The MBC all load cycle control (ALCC) replaces the current schedule-based control that has been
in use since the inception of digital control systems for GE gas turbines. ALCC controls the
overall operation of the gas turbine by changing the angle of the inlet guide vanes to adjust the
airflow, and fuel flow via the valve position to maintain the set power output within the physical
limits of the gas turbine, such as firing temperature, compressor surge margins and combustor
operability limits.
Rapid response
The ALCC constantly analyzes the turbine during operation and compares it to a theoretical
model, then adjusts its operating parameters over time based on changes in ambient conditions
and degradation of the turbine hardware. Since the system can compile an accurate picture of the
gas turbines physical state, it can increase its flexibility and performance by enabling operations
closer to its current physical boundaries, while still increasing the overall reliability of the system.
Running in conjunction with ALCC system, OpFlex Autotune software uses the same modelbased control approach for the combustion system. This software replaces a fixed split schedule
between the various combustion fuel circuits with a DLN2.6+ combustion model and control
logic to tune the splits in real time to lower emissions and dynamics. This means the combustion
system can adapt to external changes, such as ambient temperature, fuel temperature and
composition, without the need to retune it, eliminating the need for all seasonal system
adjustments, and enables the DLN2.6+ combustion system to handle up to 20 per cent variation
in natural gas energy content as measured by the MWI. This process of continual tuning helps
prevent periods of high dynamics, which can rapidly damage hardware, leading to higher repair
costs and reduced combustion intervals.
GE offers a fast start package for the 9F family that reduces the time to fire up the turbine across
the entire start sequence for both simple- and combined-cycle applications. For simple-cycle gas
turbines, start-up to full load takes only 15 minutes, enabling the gas turbine to be used as a nonspinning reserve. In combined-cycle configurations, the power plant start-up time can be reduced
by up to 20 minutes. Combining the turbine fast start with combined-cycle rapid response
products enables the turbines to be brought on-line at similar speeds to simple-cycle units and
provides opportunities as a non-spinning reserve, while also maintaining the higher efficiency of a
combined-cycle power plant during normal operation.
The package utilizes six techniques to achieve this faster start time. The purge cycle has been
moved to shortly after the gas turbine shuts down, eliminating the need to enter the purge cycle
during the start sequence. A load-commutated inverter enables the rotor to engage more quickly
with the LCI system, allowing for faster starts of the gas turbine. The LCI turns the generator into
a motor, providing the initial torque to spin the turbine until the combustion system is firing and
the turbine is producing enough power to accelerate on its own accord. When a turbine must be
restarted, fire-on-the-fly technology eliminates the hold on rotor speed during the combustion
ignition process, enabling the gas turbine to continue to accelerate.
Fast grid synchronization uses closed-loop acceleration control and incorporates a feedback to the
control system of the actual acceleration rate versus target rate to ensure a more consistent start
time to full speed and no load across the ambient temperature range. Meanwhile, advanced
control logic allows faster load acceleration to reduce the time needed to synchronize the gas
turbine generator with the grid frequency.
The turbines are also able to load from full speed and no load to full speed with full loading
roughly twice as fast in simple-cycle configurations, or with a rapid response combined-cycle
plant.
allowing the operator to take full advantage of the best fuel prices or supplies available at any
given time. There are currently 28 of these gas turbines operating in the field, which have
accumulated more than 230 000 fired hours and 3800 fired starts. The fleet leader has more than
22 500 fired hours and more than 320 fired starts.
GE is also offering a performance enhancement package for the 9FB model that delivers
incremental gas turbine performance through reducing secondary flow and drops in combustion
pressure, as well as by modulating extraction flow and reducing the pressure loss across the inlet
duct. With these improvements, the 9FB gas turbine is capable of generating 291 MW of
electricity with a heat rate of 8880 BTU/kWh of thermal energy at 38.4 per cent efficiency in
simple-cycle configuration (at ISO conditions). In a 109FB combined cycle configuration, the
unit delivers 444 MW with a heat rate of 5778 BTU/kWh and 59.1 per cent thermal baseload
efficiency (reference plant at Gas Turbine World conditions). Another benefit from the design
enhancements in this package is improved off-frequency operation.
Modular construction
The time required to construct and start up a new power plant is always going to be a critical
portion of any infrastructure schedule. The modular 9FB system requires suppliers to assemble as
much of the piping and supports as possible before reaching the field, to reduce installation costs.
Five modules are pre-assembled and assembled at the final site. Although this decreases
installation time, it also offers the opportunity to improve quality and reduce waste, since preassembly ensures the pipes are the right size. It also creates a safer working environment for the
labourers, with more ground level and shop work compared to work on-site. There are also
logistical benefits since there are fewer crates and loose parts to store, and a smaller lay-down
area. Lastly, the modular process allows faster combustion inspection and increased gas turbine
availability.