Catalogs GE

Gas Combined Cycle
Gas Turbine Design

In gas turbine design the firing temperature, compression ratio, mass flow, and centrifugal stresses are the factors limiting both unit size and efficiency. For example, each 55C (100F) increase in firing temperature gives a 10 - 13 percent output increase and a 2 - 4 percent efficiency increase. The most critical areas in the gas turbine determining the engine efficiency and life are the hot gas path, i.e., the combustion chambers and the turbine first stage stationary nozzles and rotating buckets. The components in these areas represent only 2 percent of the total cost of the gas turbine, yet they are the controlling factor in limiting gas turbine output and efficiency. The development process takes time, however, because each change of material may require years of laboratory and field tests to ensure its suitability in terms of creep strength, yield limit, fatigue strength, oxidation resistance, corrosion resistance, thermal cycling effects, etc. Manufacturers use various combustor arrangements: General Electric has several combustors mounted in a ring around the turbine; Asea Brown Boveri sometimes has a single combustor above the turbine; Siemens has two combustors, one on each side of the turbine. Gas turbines can be fueled with natural gas, diesel oil (distillate), and even residual or crude oil if appropriate customized fuel treatment facilities are installed and properly operated. Turbine nozzles and buckets are cast from nickel super alloys and are coated under vacuum with special metals (platinum-chromium-aluminide) to resist the hot corrosion that occurs ! the high temperatures encountered in the first stage of the turbine, particularly if contaminants such as sodium, vanadium and potassium are present. Only a few parts per million of these contaminants can cause hot corrosion of uncoated components at the high firing temperature encountered. With proper coating of nozzles and buckets and treatment of fuels to minimize the contaminants, manufacturers claim the hot-gas-path components should last 30,000 to 40,000 hours of operation before replacement, particularly the hot-gas-path parts, that give rise to the relatively high maintenance cost for gas turbines (typical O&M annual costs of 4 percent of the capital cost). The continuing improvements in firing temperatures and compression ratios has permitted manufacturers to increase the operating performance on the same basic gas turbine frame or housing. For example, General Electric introduced its Frame 7 series in 1970 with a rating of 45 MW, a firing temperature of 900C (1650 F) and an air flow of 0.8 million kgs (1.8 million lbs) per hour. Through many changes and upgrades the latest Model F of the same Frame 7 series has a rating of 147 MW, a firing temperature of 1260C (2300F) and an air flow of 1.5 million kgs (3.3 million lbs) per hour. One of the major advances made was to air cool nozzles and buckets using bleed air from the compressor to increase the firing temperature while limiting the metal temperatures of the nozzles and buckets to withstand hot corrosion and creep. This limiting of the
maximum temperature through air cooling while simultaneously increasing the mass flow with more air compressor capacity permits higher power output. To increase the final compressor pressure additional compressor stages are added on the compressor rotor assembly to give higher compression ratio thus providing additional turbine power output. Typical industrial gas turbine compression ratios are 16:1 and aeroderivative ratios are 30:1 with roughly 50 percent of the total turbine power of either type being required just to drive the compressor. Compressor blading is special stainless steel, possibly coated by electroplating with nickel and cadmium to resist pitting in salt and acid environments. Compressor designs have been quite effective, as evident by the 200,000-hour life of some early compressors installed in the 1950s. The gas turbine has the inherent disadvantage that reduced air density with high ambient temperature or high elevation causes a significant reduction in power output and efficiency, because the mass flow through the gas turbine is reduced. A 28C (50F) results in about a 25 percent output reduction and a 10 percent higher heat rate. Similarly, at 1000 meter (3300 ft) elevation the gas turbine output would be 15 percent lower than at sea level. Steam plants and diesels are not affected to the same degree by ambient air temperature and elevation changes.
Aeroderivitive Versus Industrial Gas Turbines

The advanced gas turbine designs available today are largely due to the huge sums that have been spent over the last 50 years to develop effective jet engines for military applications, including their adaptation as gas turbine propulsion systems for naval vessels. The commercial aviation, electric power and to a lesser extent, the sea and land transportation industries, have benefited accordingly. Given the aircraft designer's need for engine minimum weight, maximum thrust, high reliability, long life and compactness, it follows that the cutting-edge gas turbine developments in materials, metallurgy and thermodynamic designs have occurred in the aircraft engine designs, with subsequent transfer to land and sea gas turbine applications. However, there are weight and size limitations to aircraft engine designs, whereas the stationary power gas turbine designers are seeking ever larger unit sizes and higher efficiency. To emphasize this difference in approach, today the largest aeroderivative power gas turbine is probably General Electric's 40 MW LM6000 engine with a 40 percent simple-cycle efficiency and a weight of only 6 tons. This engine is adapted from the CF6-80C2 engine that is used on the CF6 military transport aircraft. By comparison, General Electric's largest industrial gas turbine, the Frame 9 Model F has an output of about 200 MW, an open-cycle efficiency of 34 percent, but is huge compared to the LM6000 and weights 400 tons. The aeroderivative is a light weight, close clearance, high efficiency power gas turbine suited to smaller systems. The industrial or frame type gas turbine tends to be a larger, more rugged, slightly less efficient power source, better suited to base-load operation, particularly if arranged in a combined-cycle block on large
systems. There is no significant difference in availability of two types of gas turbines for power use, based on the August 1990 Generation Availability Report of the North American Electric Reliability Council. For the period 19851989 the average availability of 347 jet engines (1587 unit years) was 92 percent and that for 575 industrial gas turbines (2658 unit years) was 91 percent.
Combined Cycle Sizes/Costs

Gas turbines of about 150 MW size are already in operation manufactured by at least four separate groups-General Electric and its licensees, Asea Brown Boveri, Siemens, and Westinghouse/Mitsubishi. These groups are also developing, testing and/or marketing gas turbine sizes of about 200 MW. Combined-cycle units are made up of one or more such gas turbines, each with a waste heat steam generator arranged to supply steam to a single steam turbine, thus formatting a combined-cycle unit or block. Typical combined-cycle block sizes offered by three major manufacturers (Asea Brown Boveri, General Electric and Siemens) are roughly in the range of 50 MW to 500 MW and costs are about $600/kW.
Combined Cycle Efficiencies

Combined-cycle efficiencies are already over 50 percent and research aimed at 1370C (2500F) turbine inlet temperature may make 60 percent efficiency possible by the turn of the century, according to some gas turbine manufacturers.
Low-Grade Fuel for Turbines

Gas turbines burn mainly natural gas and light oil. Crude oil, residual, and some distillates contain corrosive components and as such require fuel treatment equipment. In addition, ash deposits from these fuels result in gas turbine deratings of up to 15 percent They may still be economically attractive fuels however, particularly in combined-cycle plants. Sodium and potassium are removed from residual, crude and heavy distillates by a water washing procedure. A simpler and less expensive purification system will do the same job for light crude and light distillates. A magnesium additive system may also be needed to reduce the corrosive effects if vanadium is present. Fuels requiring such treatment must have a separate fuel-treatment plant and a system of accurate fuel monitoring to assure reliable, low-maintenance operation of gas turbines.
Alternative Combined Cycle Designs

Gas dampers are often provided so the gas turbine exhaust can bypass the heat recovery boiler allowing the gas turbine to operate if the steam unit is down for maintenance. In earlier designs supplementary oil or gas firing was also included to permit steam unit operation with the gas turbine down. This is not normally provided on recent combined-cycle designs, because it adds to the capital cost, complicates the control system, and reduced efficiency. Sometimes as many as four gas turbines with individual boilers may be associated with a single steam turbine. The gas turbine, steam turbine, and generator may be arranged as a single-shaft design, or a multishaft arrangement may be used with each gas turbine driving a generator and exhausting into its heat recovery boiler with all boilers supplying a separate steam turbine and generator. Combined-Cycle Shaft Arrangements
Combined Cycle Modular Installations One significant advantage of combined-cycle units is that the capacity can be installed in stages with short lead time gas turbines being installed initially (1 to 2 years) followed later by heat recovery boilers with the steam turbines (3 years total). In this way each combined-cycle unit (i.e. block) can be installed in three (or more) roughly equal capacity segments. The modular arrangement of combined-cycle units also facilitates generation dispatching because each gas turbine can be operated independently (with or without the steam turbine) if part of the combined-cycle unit is down for maintenance or if less than the combined-cycle unit total capacity is required. This may give a higher efficiency for small loading than if the total capacity was operated.
Furthermore, since combined-cycle units are available in sizes of roughly 50 MW to almost 500 MW (and 600 MW are expected to be available soon with 200 MW gas turbines), there are many selection possibilities for most sizes of power system. Another point favoring staging a combined-cycle unit is that the gas turbine (or combined-cycle) per kilowatt cost does not seem to increase significantly for smaller units, as is the case for steam units due partly to the high cost of the substantial civil works necessary for steam plants regardless of steam unit size. Finally, combined-cycle units can be installed in 3 years while a steam unit typically requires 5 years, and once committed there is no power output from a steam unit until the complete unit is available.
Fuels for Combined Cycles Using present technology the combined-cycle unit can be fueled with natural gas, distillate, and even crude or residual oil with appropriate fuel treatment. Fueling with crude or residual oil, however, definitely results in extra capital costs for fuel treatment equipment. Operations suffer due to additional operating costs for additives to counteract contaminants such as vanadium, lower availability due to additional maintenance and water cleaning shutdowns to remove blade deposits, and reduced life because there is a greater tendency for hot gas path corrosion due to blade deposits and corrosion. The daily (or even more frequent) testing of the residual or crude oil for contaminants with appropriate adjustments of fuel treatment is critical to prevent damage to the gas turbine. Even with good operation there will be a reduction in efficiency with crude or residual oil fueling to reduce firing temperatures, as recommended by most manufacturers for this mode of operation, and due to the blade deposits which build up between water-washing intervals. The gas turbine has to be shut down periodically for cleaning and allowed to cool before washing can be done by injecting water while rotating the unit using the starting motor.
Operational Considerations of Combined Cycles This gas turbine is the main component that requires maintenance on combined-cycle units. All manufacturers recommend specific intervals for hotgas-path inspections and for major overhauls, which usually involve hot-gaspath part changes. During overhauls the condition of aeroderivatives may require that the complete engine or at least major components be sent to overhaul centers, while the industrial gas turbines usually will require only part changes on site.
The type of fuel and mode of operation are critical in determining both the maintenance intervals and the amount of maintenance work required. It is estimated by one manufacturer that burning residual or crude oil will increase maintenance costs by a factor of 3, assuming a base of 1 for natural gas, and by a factor of 1.5 for distillate fueling. Similarly, maintenance costs will be three times higher for the same number of fired hours if the unit is started, i.e. cycled, once every fired hour, instead of starting once very 1000 .fired hours. Peaking at 110 percent of rating will increase maintenance costs by a factor of 3 relative to base-load operation at rated capacity, for the same number of fired hours. The control system on combined-cycle units is largely automatic so, after a start is initiated by an operator, the unit accelerates, synchronizes and loads with automatic monitoring and adjustment of unit conditions in accordance with present programs. The number of operators required in a combined-cycle plant therefore is lower than in a steam plant.
Developed Country Combined Cycle Installations The following key topics provide examples of developed country combinedcycle installations. Electricity Supply Board of Ireland Oil-to-Gas Conversion The electricity Supply Board of Ireland converted two old oil-fired steam plants to gas-fired combined cycle units in the late 1970s. Originally, there units were used for baseloaded operation, but recently change to intermediate load. Refer To: World Bank IEN Working Paper #35: "Prospects for Gas-Fueled Combined-Cycle Power Generation in the Developing Countries", May 1991. Midland Nuclear Plant Conversion, U.S.A. Twelve Asea Brown Boveri 85 MW gas turbines and heat recovery boilers were installed to supply two 350 MW steam units originally installed for the Midland nuclear plant. This combined-cycle cogeneration plant will supply 1380 MW to Consumer Power Co. and process steam plus 60 MW of power to Dow Chemical Co. Refer To: World Bank IEN Working Paper #35: "Prospects for Gas-Fueled Combined-Cycle Power Generation in the Developing Countries", May 1991. LNG-Fired Combined-Cycle by Tokyo Electric The world's largest regasified LNG-fueled combined-cycle plant is in operation near Tokyo in Japan. Fourteen 165 MW single-shaft combined-cycle units serve as mixed base-load and mid-range generation on the 41,000 MW Tokyo Electric Power Co. system. The plant capacity is 2,310 MW at 15C ambient decreasing to 2,000 MW at 32C. A unique feature is the low NOx emission level of 10 ppm due to the use of selective catalytic reduction equipment.
Refer To: World Bank, IEN Working Paper #35: "Prospects for Gas-Fueled Combined-Cycle Power Generation in the Developing Countries", May 1991.
Developing Country Combined Cycle Installations The following list provides examples of Combined Cycle projects in developing countries. These examples are discussed in greater detail in the associated Key Topics. 5 x 300 MW in India 3 x 300 MW Gas Turbines in Malaysia 2 x 300 MW in Pakistan 5 Combined-Cycle plants in Mexico 300 MW in Egypt 772 MW in Thailand Combined-Cycle in Bangladesh
The dollar per kilowatt capacity costs vary from $592/kW for a new 1,080 MW combined-cycle plant in Egypt to $875/kW for a steam addition to convert four gas turbines at Multan in Pakistan to a combined-cycle plant. Although the operating performance of combined-cycle units in North America is reported to be satisfactory with availability factors of about 85 percent, the developing country experience is less favorable, and in some countries the performance has been poor.
GE Energy
GAS TURBINE AND COMBINED CYCLE PRODUCTS
The Power of Technology, Experience and Innovation
The world demands a reliable supply of clean, dependable power. Always on the cutting edge of gas
turbine technology, GE offers a wide array of technological options to meet the most challenging
energy requirements. Using an integrated approach that includes parts, service, repair and project
management, we deliver results that contribute to our customers success. And our reputation for
excellence can be seen in everything we do.
GE ENERGY GAS TURBINE AND COMBINED CYCLE PRODUCTS
Heavy Duty Output CC CC CC CC 280.3 MW 412.9 MW 50 Hz 60 Hz 400 MW 60 Hz 520 MW 50 Hz

2 2 6 6
Heat Rate Btu/kWh kJ/kWh 5,690 5,690 5,880 5,950 6,000 6,000 6,202 6,276
MS9001H MS7001H MS9001FB MS7001FB
MS6001FA
CC CC SC SC CC SC CC SC CC SC CC SC
117.7 MW 118.1 MW 75.9 MW 75.9 MW 262.6 MW 171.7 MW 390.8 MW 255.6 MW 193.2 MW 126.1 MW 130.2 MW 85.1 MW
50 Hz 60 Hz 50 Hz 60 Hz 60 Hz 60 Hz 50 Hz 50 Hz 50 Hz 50 Hz 60 Hz 60 Hz
6,240 6,250 9,760 9,795 6,090 9,360 6,020 9,250 6,570 10,100 6,800 10,430
6,582 6,593 10,295 10,332 6,424 9,873 6,350 9,757 6,930 10,653 7,173 11,002
MS7001FA
MS9001FA
10
MS9001E
11
MS7001EA
12
MS6001B
CC CC SC
64.3 MW 64.3 MW 42.1 MW
50 Hz 60 Hz 50/60 Hz
6,950 6,960 10,642
7,341 7,341 11,226
13
MS6001C
CC CC SC SC
14
67.2 MW 67.2 MW 45.4 MW 45.3 MW
50 Hz 60 Hz 50 Hz 60 Hz Small Heavy-Duty and Aeroderivative Gas Turbine Products Overview

16
6,281 6,281 9,315 9,340
6,627 6,627 9,830 9,855
IGCC (Integrated Gasification Combined Cycle) Overview

NOTE: All ratings are net plant based on ISO conditions and natural gas fuel. All CC ratings shown above are based on a 1 GT/1 ST configuration.
H System
MS9001H/MS7001H COMBINED CYCLE PERFORMANCE RATINGS
Net Plant Heat Rate Output (MW) (Btu/kWh) (kJ/kWh) Net Plant Efficiency 60.0% GT Number & Type 1 x MS9001H
Worlds Most Advanced Combined Cycle Gas Turbine Technology
H SYSTEM
GEs H Systemthe worlds most advanced combined cycle system and the first capable of breaking
the 60% efficiency barrierintegrates the gas turbine, steam turbine, generator and heat recovery steam
50 Hz
S109H 520 5,690
generator into a seamless system, optimizing each components performance. Undoubtedly the leading
60 Hz
S107H 400 5,690
6,000
technology for both 50 and 60 Hz applications, the H delivers higher efficiency and output to reduce the
cost of electricity of this gas-fired power generation system.
6,000
60.0%
1 x MS7001H
Closed-Loop Steam Cooling
Open loop air-cooled gas turbines have a significant temperature drop across the first stage nozzles, which
reduces firing temperature and thermal efficiency. The closed-loop steam cooling system allows the turbine
to fire at a higher temperature for increased performance. It is this closed-loop steam cooling that enables
Baglan Bay Power Station is the launch site for GEs H System.
the H System to achieve 60% fuel efficiency capability while maintaining adherence to the strictest low NOx
standards and reducing CO2 emissions. Additionally, closed-loop cooling also minimizes parasitic extraction
of compressor discharge air, thereby allowing more air to flow to the combustor for fuel premixing, thereby
enabling lower emissions.
An MS9001H is seen during assembly in the factory.
RDC27903-13-03
PSP30462-05
Single Crystal Materials
3
H SYSTEM
The use of these advanced materials and Thermal Barrier Coatings ensures that components will stand
up to high firing temperatures while meeting maintenance intervals.
Dry Low NOx Combustors

A 9H gas turbine is readied for testing.
Building on GEs design experience, the H System employs a can-annular lean pre-mix DLN-2.5
Dry Low NOx (DLN) Combustor System. Fourteen combustion chambers are used on the 9H, and
12 combustion chambers are used on the 7H. GE DLN combustion systems have demonstrated
RDC27916-09-09
the ability to achieve low NOx levels in several million hours of field service around the world.
Small Footprint/High Power Density
The H System offers approximately 40% improvement in power density per installed megawatt
compared to other combined cycle systems, once again helping to reduce the overall cost of
producing electricity.
Thoroughly Tested
PSP30246-10
The design, development and validation of the H System has been conducted under a regimen of extensive
Worlds first H turbine is transported through Wales to Baglan Bay Power Station.
component, sub-system and full unit testing. Broad commercial introduction has been controlled to follow
launch units demonstration. This thorough testing approach provides the introduction of cutting edge tech-
nology with high customer confidence.
F Class
Worlds Most Experienced Advanced Technology Gas Turbines
F CLASS
With over ten million hours of operation, our F class turbines have established GE as the clear industry
leader for successful fired hours in advanced technology gas turbines. Representing the worlds largest,
most experienced fleet of highly efficient gas turbines, designed for maximum reliability and efficiency
with low life cycle costs, our F class turbines are favored by both power generators and industrial
cogenerators requiring large blocks of reliable power.
Introduced in 1987, GEs F class gas turbines resulted from a multi-year development program using
technology advanced by GEs aircraft engine team and GE Global Research. GE continually advances
this technology by incrementally improving the F class product to attain ever higher combined cycle
PSP30027-06
efficiencies, while maintaining reliability and availability.
An MS9001FA gas turbine ships from the plant.
Dry Low NOx combustor systems allow GEs F Class turbines to meet todays strict environmental emissions requirements.
RDC27305-02a
Our F class gas turbines, including the 6F (either 50 or 60 Hz), the 7F (60 Hz) and the 9F (50 Hz), offer
5
F CLASS
flexibility in cycle configuration, fuel selection and site adaptation. All F class gas turbines include an
18-stage axial compressor and a three-stage turbine, and they feature a cold-end drive and axial exhaust,
which is beneficial for combined cycle arrangements where net efficiencies over 58% can be achieved.
F/FA/FB EXPERIENCE
14000
11,844 11,594 10,327 9,061
12000
10000
8000
6000
FIRED HOURS IN THOUSANDS
4000
7,794 6,859 5,790 4,899 4,186 3,575 2,989
2000
0 95 96 97 98 99 00 01 02 03 04 05
YEAR
Half of all 6FA installations are located in Europe. This CHP plant is owned by Porvoo,
PSP30114
Finland.
PSP30210-01
MS7001FB and MS9001FB
Worlds Most Advanced Air-Cooled Gas Turbine
The FB is the latest evolutionary step in GEs proven F series. Taking F technology to a new level of output
and efficiency, weve applied our cutting-edge technology, including the materials developed for the
H System, and the experience gained in over ten million advanced gas turbine fired hours. The result is a
large combined cycle system designed to provide high performance and low electrical cost.
This MS9001FB is seen on half shell during assembly.
Improved output and efficiency means better fuel economy and reduced cost of producing electricity. With
todays competitive markets and unpredictable fuel prices, thisnow more than everis the key to success.
Hunterstown, PA 7FB launch site.

PSP30251-39
PSP30371-02
This MS7001FB is shown in the factory.
PSP30510-01
In developing the FB, we followed a specific course that significantly improved the key driver of efficiency
MS7001FB/MS9001FB COMBINED CYCLE PERFORMANCE RATINGS
Heat Rate Net Plant Output (MW) (Btu/kWh) (kJ/kWh) S109FB S209FB S107FB S207FB 562.5 280.3 5,950 5,940 825.4 5,884 412.9 5,880 6,202 6,206 6,276 6,266
firing temperature. The FB firing temperature was increased more than 100 degrees Fahrenheit over GEs FA
technology, resulting in combined cycle efficiency rating improvements of better than one percentage
Net Plant Efficiency 58.0% 58.0% 57.3% 57.5%
GT Number & Type 1 x MS9001FB 2 x MS9001FB 1 x MS7001FB 2 x MS7001FB
point. Output improvements of more than 5% were also achieved. These improvements equate to more MW
60 Hz 50 Hz
per MBtu of natural gas burned.
The use of advanced turbine materials, such as Single Crystal First Stage Buckets, ensures that components
can stand up to the higher firing temperatures of the FB without an increase in maintenance intervals.
Providing the basis of process rigor, Six Sigma methodologies were used to assure a highly reliable robust
design optimized for lowest cost of electricity. Indeed, in developing the FB, we were able to maintain many
of the proven features of the worlds most successful advanced technology turbine, the F/FA.
An MS7001FB is seen in test cell.
PSP30299
PSP30266-02
MS6001FA, MS7001FA and MS9001FA

MS6001FA SIMPLE CYCLE PERFORMANCE RATINGS
50 Hz Power Generation Output Heat Rate Pressure Ratio Mass Flow Turbine Speed Exhaust Temperature Model Designation (F) (C) (rpm) (lb/sec) (kg/sec) 447 203 5,231 1,117 603 PG6111FA 15.6:1 (Btu/kWh) (kJ/kWh) 9,760 10,295 (MW) 75.9 75.9 9.795 10,332 15.7:1 449 204 5,254 1,118 603 PG6111FA 60 Hz Power Generation
Proven Performance in a Mid-Size Package
The highly efficient gear-driven 6FA gas turbine is a mid-size version of the well-proven 7FA and 9FA. Its
output range, high exhaust energy, full packaging and robust design ideally suit applications ranging from
cogeneration and district heating to pure power generation in combined cycle and Integrated Gasification
Combined Cycle (IGCC).
M S 6 0 0 1 FA , M S 7 0 0 1 FA a n d M S 9 0 0 1 FA
To meet the need for mid-size power blocks with high performance in combined heat and power
MS6001FA COMBINED CYCLE PERFORMANCE RATINGS
Heat Rate Net Plant Output (MW) (Btu/kWh) (kJ/kWh) S106FA S206FA S106FA S206FA 117.7 237.9 118.1 237.5 6,240 6,170 6,250 6,210 6,582 6,508 6,593 6,550 Net Plant Efficiency 54.7% 55.3% 54.6% 54.9% GT Number & Type 1 x MS6001FA 2 x MS6001FA 1 x MS6001FA 2 x MS6001FA
applications, the high-speed 6FA produces 75.9 MW of simple cycle power at 35% efficiency and
117 MW of combined cycle power at 54.7% net efficiency. In IGCC operation, gross plant efficiencies
can reach up to 46%.

60 Hz 50 Hz
A classic example of GEs evolutionary designs, the 6FA is a 2/3 scale of the 7FA. Its aerodynamically
scaled 18-stage axial design reduces combustion chambers from 14 to 6. A cold-end drive allows exhaust
gases to be directed axially into the HRSG. With over 860,000 operating hours and 61 units installed or on
order, the 6FA provides major fuel savings over earlier mid-range units in base-load operation. Adaptable
to single or multi-shaft configurations, it burns a variety of fossil fuels, which can be switched after start-up
without sacrificing performance. On natural gas the available Dry Low NOx (DLN) system can achieve NOx
KEPCOs Seoinchon Plant, one of the worlds largest combined cycle plants, has operated for more than 40,000 hours in daily start/stop cyclic duty.
emissions of 15 ppm.
Industry Standard for 60 Hz Power in All Duty Cycles
The wide range of power generation applications for the 7FA gas turbine includes combined cycle, cogenera-
tion, simple cycle peaking and IGCC in both cycle and base load operation with a wide range of fuels. Its high
overall life cycle cost.
RDC27834-34
reliabilityconsistently 98% or betterprovides customers more days of operation per year while minimizing

60 Hz Power Generation Output Heat Rate Pressure Ratio Mass Flow Turbine Speed Exhaust Temperature Model Designation (F) (C) (rpm) (lb/sec) (kg/sec) 981 445 3,600 1,114 601 PG7241FA 16.0:1 (Btu/kWh) (kJ/kWh) 9,360 9,873 (MW) 171.7
As an industry leader in reducing emissions, the 7FAs DLN-2.6 combustor (proven in hundreds of thousands
of operating hours) produces less than 9 ppm NOx and COminimizing the need for exhaust cleanup sys-
tems and saving millions for our customers.
With 100s of units in operation, GE continually makes incremental design enhancements to improve output,
efficiency, reliability and availabilityfor new units and upgrades to existing units. GE adds customer value
M S 6 0 0 1 FA , M S 7 0 0 1 FA a n d M S 9 0 0 1 FA
with power augmentation equipment that provides additional gas turbine performance in summer peak
Net Plant Heat Rate Output (MW) (Btu/kWh) (kJ/kWh) Net Plant Efficiency 262.6 S207FA 529.9 6,090 6,040 6,424 6,371 56.0% 56.5% GT Number & Type 1 x MS7001FA 2 x MS7001FA
demand periodsincluding inlet cooling, steam injection, and peak firing.
Power producers around the world require reliable power generationwhich makes the 9FA the 50 Hz gas
turbine of choice for large combined cycle applications. As an aerodynamic scale of the highly successful
50 Hz Power Generation Output Heat Rate Pressure Ratio Mass Flow Turbine Speed Exhaust Temperature Model Designation (lb/sec) (kg/sec) (rpm) (F) (C) (MW) (Btu/kWh) (kJ/kWh) 255.6 9,250 9,757 17.0:1 1,413 641 3,000 1,116 602 PG9351FA
7FA gas turbine, the 9FA provides key advantages that include a fuel-flexible combustion system and higher
output performance.
The 9FA gas turbine is configured with the robust DLN-2.0+. Ideally suited for diverse fuels, this combustor
is the industry leader in pollution prevention for 50 Hz combined cycle applications with greater than 56%
efficiency, achieving less than 25 ppm NOx.
The 9FA can be configured to meet site and power requirements. For re-powering applications with space
limitations, it can be configured in a single-shaft combined cycle arrangement with the generator and steam
turbine. For large combined cycle or cogeneration plants where flexible operation and maximum perform-
ance is the prime consideration, it can be arranged in a multi-shaft configuration where one or two gas

Net Plant Heat Rate Output (MW) (Btu/kWh) (kJ/kWh) Net Plant Efficiency GT Number & Type
turbines are combined with a single steam turbine to produce power blocks of 390 or 786 MW.
50 Hz
S109FA S209FA
60 Hz
Proven Excellence in Reliable 50 Hz Combined Cycle Performance
S107FA
390.8 786.9
6,020 5,980
6,350 6,308
56.7% 57.1%
1 x MS9001FA 2 x MS9001FA
MS9001E
MS9001E SIMPLE CYCLE PERFORMANCE RATINGS
50 Hz Power Generation Output (MW) (Btu/kWh) (kJ/kWh) Heat Rate Pressure Ratio Mass Flow Turbine Speed Exhaust Temperature Model Designation (lb/sec) (kg/sec) (rpm) (F) (C) 126.1 10,100 10,653 12.6:1 922 418 3,000 1,009 543 PG9171E
10
Fuel-Flexible 50 Hz Performer
MS9001E
The MS9001E gas turbine is GEs 50 Hz workhorse. With more than 390 units, it has accumulated over
14 million fired hours of utility and industrial service, many in arduous climates ranging from desert heat
and tropical humidity to arctic cold. Originally introduced in 1978 at 105 MW, the 9E has incorporated
numerous component improvements. The latest model boasts an output of 126 MW and is capable of
achieving more than 52% efficiency in combined cycle.
Whether for simple cycle or combined cycle application, base load or peaking duty, 9E packages are
comprehensively engineered with integrated systems that include controls, auxiliaries, ducts and silencing.
They are designed for reliable operation and minimal maintenance at a competitively low installed cost.
MS9001E COMBINED CYCLE PERFORMANCE RATINGS
Heat Rate Net Plant Output (MW) (Btu/kWh) (kJ/kWh) Net Plant Efficiency GT Number & Type
Like GEs other E-class technology units, the Dry Low NOx combustion system is available on 9E, which can
50 Hz
S109E S209E
achieve NOx emissions under 15 ppm when burning natural gas.
193.2 391.4
6,570 6,480
6,930 6,835
52.0% 52.7%
1 x MS9001E 2 x MS9001E
With its flexible fuel handling capabilities, the 9E accommodates a wide range of fuels, including natural
gas, light and heavy distillate oil, naphtha, crude oil and residual oil. Designed for dual-fuel operation,
it is able to switch from one fuel to another while running under load. It is also able to burn a variety of
syngases produced from oil or coal without turbine modification. This flexibility, along with its extensive
The MS9001E gas turbine is designed to attain high availability levels and low maintenance costs, resulting in extremely low total cost of ownership.
experience and reliability record, makes the 9E well suited for IGCC projects.
In simple cycle, the MS9001E is a reliable, low first-cost machine for peaking service, while its high
combined cycle efficiency gives excellent fuel savings in base load operations. Its compact design
provides flexibility in plant layout as well as the easy addition of increments of power when a phased
capacity expansion is required.

RDC26213-12
MS7001EA
MS7001EA SIMPLE CYCLE PERFORMANCE RATINGS
60 Hz Power Generation Output (MW) (Btu/kWh) (kJ/kWh) 85.1 10,430 11,002 12.7:1 (lb/sec) (kg/sec) (rpm) (F) (C) 648 294 3,600 997 536 PG7121EA (lb/sec) (kg/sec) (rpm) (F) (C) Heat Rate Pressure Ratio Mass Flow Turbine Speed Exhaust Temperature Model Designation Mechanical Drive (hp) (Btu/shp-hr) 115,630 7,720 11.9:1 659 299 3,600 999 537 M7121EA
Time-Tested Performer for 60 Hz Applications
11
MS7001EA
With more than 750 units in service, the 7E/EA fleet has accumulated tens of millions of hours of service
and is well recognized for high reliability and availability.
With strong efficiency performance in simple and combined cycle applications, this 85 MW machine is
used in a wide variety of power generation, industrial and cogeneration applications. It is uncomplicated
and versatile; its medium-size design lends itself to flexibility in plant layout and fast, low-cost additions
of incremental power.
With state-of-the-art fuel handling equipment, advanced bucket cooling, thermal barrier coatings and
MS7001EA COMBINED CYCLE PERFORMANCE RATINGS
Net Plant Heat Rate Output (MW) (Btu/kWh) (kJ/kWh) Net Plant Efficiency GT Number & Type
a multiple-fuel combustion system, the 7EA can accommodate a full range of fuels. It is designed for dual-
fuel operation, able to switch from one fuel to another while the turbine is running under load or during
shutdown. 7E/EA units have accumulated millions of hours of operation using crude and residual oils.
60 Hz
S107EA 130.2 S207EA 263.6
6,800 6,700
7,173 7,067
50.2% 50.9%
1 x MS7001EA 2 x MS7001EA
In addition to power generation, the 7EA is also well suited for mechanical drive applications.
An MS7001EA is shown on half shell during assembly.
GT20821
MS6001B
MS6001B SIMPLE CYCLE PERFORMANCE RATINGS
50/60 Hz Power Generation Mechanical Drive Output Heat Rate (Btu/kWh) (kJ/kWh) Pressure Ratio Mass Flow Turbine Speed Exhaust Temperature Model Designation (lb/sec) (kg/sec) (rpm) (F) (C) (MW) 42.1 10,642 11,226 12.2:1 311 141 5,163 1,018 548 PG6581B (lb/sec) (kg/sec) (rpm) (F) (C) (hp) 58,380 (Btu/shp-hr) 7,650 12.0:1 309 140 5,111 1,011 544 M6581B
12
Reliable and Rugged 50/60 Hz Power
MS6001B
The MS6001B is a performance proven 40 MW class gas turbine, designed for reliable 50/60 Hz power
generation and 50,000 hp class mechanical drive service. With availability well documented at 97.1% and
reliability at 99.3%, it is the popular choice for efficient, low installed cost power generation or prime movers
in mid-range service.
With over 980 units in service, the versatile and widely used 6B gas turbine has accumulated over
45 million operating hours in a broad range of applications: simple cycle, heat recovery, combined cycle,
and mechanical drive. It can be installed fast for quick near-term capacity.
The rugged and reliable 6B can handle multiple start-ups required for peak load. It can accommodate a
MS6001B COMBINED CYCLE PERFORMANCE RATINGS

Heat Rate Net Plant Output (MW) (Btu/kWh) (kJ/kWh) S106B 64.3 6,950 7,341 Net Plant Efficiency 49.0% GT Number & Type 1 x MS6001B
variety of fuels and is well suited to IGCC. In combined cycle operation the 6B is a solid performer at nearly
50% efficiency. It is also a flexible choice for cogeneration applications capable of producing a thermal
50 Hz
S206B S406B S106B
output ranging from 20 to 400 million Btu/hr.
130.7 261.3 64.3
6,850 6,850 6,960
7,225 7,225 7,341
49.8% 49.8% 49.0%
2 x MS6001B 4 x MS6001B 1 x MS6001B
Like all GE heavy-duty gas turbines, the 6B has earned a solid reputation for high reliability and environ60 Hz
mental compatibility. With a Dry Low NOx combustion system, the 6B is capable of achieving less than
S206B S406B
130.7 261.3
6,850 6,850
7,225 7,225
49.8% 49.8%
2 x MS6001B 4 x MS6001B
15 ppm NOx on natural gas.
With its excellent fuel efficiency, low cost per horsepower and high horsepower per square foot, the MS6001B
is an excellent fit for selective mechanical applications.
An MS6001B rotor is seen on half shell.

RDC24656-03
MS6001C
MS6001C SIMPLE CYCLE PERFORMANCE RATINGS
50 Hz Output (MW) (Btu/kWh) (kJ/kWh) Heat Rate Pressure Ratio Mass Flow Turbine Speed Exhaust Temperature Model Designation (lb/sec) (kg/sec) (rpm) (F) (C) 45.4 9,315 9,830 19.6:1 270 122 7,100 1,078 581 60 Hz 45.3 9,340 9,855 19.6:1 270 122 7,100 1,078 581 PG6591C
High Efficiency 45 MW Class Gas Turbine
13
MS6001C
The 6C meets the need for low-cost electricity production in heat recovery operations for both 50 and 60 Hz
including industrial cogeneration, district heating, and mid-sized combined-cycle power plants.
Consistent with GEs evolutionary design philosophy, the 6C incorporates technologies that have been validated
in service worldwide. This evolutionary approach ensures users of the 6C that they are receiving advanced
but well-proven technology. The Frame 6C builds on the experience and performance of GEs Frame 6B
technology, proven in more than 45 million hours of service, and also incorporates key features of GEs
advanced F technology.
The turbine includes components that provide high reliability and maintainability, such as a 12-stage compressor
MS6001C COMBINED CYCLE PERFORMANCE RATINGS

Heat Rate Net Plant Output (MW) (Btu/kWh) (kJ/kWh) S106C S206C S106C S206C 67.2 136.1 67.2 136.1 6,281 6,203 6,281 6,203 6,627 6,544 6,627 6,544 Net Plant Efficiency 54.3% 55.0% 54.3% 55.0% GT Number & Type 1 x MS6001C 2 x MS6001C 1 x MS6001C 2 x MS6001C
with fewer parts and removable blades and vanes. NOx emissions are limited to 15 ppm dry when operating
on natural gas, and 42 ppm when burning light distillate with water injection.
Improved operability features include less than 50%
and reliable starts in 13 minutes, and three stages of
compressor guide vanes for high efficiency at part load.
The 6C also features an F-class modular arrangement
and a Mark VI Speedtronic control system.
Akenerji Kemalpasa-Izmir Turkey 206C Combined-CycleCOD since November 2005 Rigorous field validation tests conducted at the Kemalpasa 6C launch site confirmed the outstanding operability of the turbinehigh efficiency and low emissions.
PSP30646-02
60 Hz 50 Hz
turndown while maintaining emissions guarantees, fast
Small Heavy-Duty and Aeroderivative Gas Turbines
14
A Broad Portfolio of Packaged Power Plants
GE provides a broad range of power packages from 5 MW to nearly 50 MW for simple cycle, combined
cycle or cogeneration applications in the utility, private and mobile power industries. Marine applications
for these machines range from commercial fast ferries and cruise ships to military patrol boats, frigates,
destroyers and aircraft carriers.
Oil & Gas
GE is a world leader in high-technology turbine products and services for the oil & gas industry.
RDC26874-04
We offer full turnkey systems and aftermarket solutions for production, LNG, transportation, storage,
S M A L L H E AV Y - D U T Y a n d A E R O D E R I VAT I V E G A S T U R B I N E S
refineries, petrochemical and distribution systems.

The powerful LM6000 is one of the most fuel-efficient simple cycle gas turbines in the world.
SMALL HEAVY-DUTY GAS TURBINES

Output (kW) Heat Rate (Btu/kWh) (kJ/kWh) 11,130 10,884 12,028 Heat Rate (Btu/shp-h) 8,080 10,543 8,814 8,650 10.8:1 8.8:1 15.5:1 7,900 4,670 4,670 14.6:1 12,500 Pressure Ratio Turbine Speed (rpm) 12,687 10.5:1 5,094 276.1 11,481 15.5:1 11,000 104.7 47.5 125.2 11,740 14.8:1 16,630 43.1 19.6 1,065 900 901 5,500 11,250 26,830 Output (shp) 7,510 15,575 38,005 43,690 Pressure Ratio Turbine Speed (rpm) Exhaust Flow (lb/sec) (kg/sec) Exhaust Temp. (F) (C) 574 482 483 Exhaust Temp. (F) (C) 44.2 103.3 274.1 311.7 20.0 46.9 123.4 141.4 1032 903 963 948 556 484 517 509
GE5
Generator Drive*
GE10
MS5001
Exhaust Flow (lb/sec) (kg/sec)
GE5
GE10
Mechanical Drive**
MS5002C
MS5002E
*ISO conditions natural gas electrical generator terminals **ISO conditions natural gas shaft output
AERODERIVATIVE GAS TURBINES

Output (kW) Heat Rate (Btu/kWh) (kJ/kWh) 7,563 7,569 8,461 8,173 8,272 8,374 8,452 8,880 8,901 8,673 9,630 9,779 9,749 7,569 7,582 8,434 8,112 8,235 8,308 8,415 8,753 8,774 8,391 9,315 9,587 9,735 Heat Rate (Btu/shp-h) 5,941 6,435 6,450 6,780 6,992 7,016 23:1 19.5:1 15.6:1 20.2:1 23:1 29.1:1 Pressure Ratio 10,268 20.2:1 7,900 Turbine Speed (rpm) 3,600 3,600 3,600 3,600 3,600 7,900 10,112 15.6:1 3,600 9,825 19.1:1 3,600 153 139 104 8,850 19.4:1 3,600 167 9,257 23:1 3,600 201 91 76 69 63 47 Exhaust Flow (lb/sec) (kg/sec) 282 202 200.9 152 138.6 104.3 127.9 92.0 91.1 69.0 62.9 47.3 9,235 23:1 3,600 201.9 91.6 8,876 28.1:1 3,600 268 122 8,763 29.3:1 3,600 278 126 846 857 976 977 922 992 886 894 8,686 30.7:1 3,600 290 132 837 8,557 29.1:1 3,600 282 128 824 440 447 458 524 525 494 533 474 479 Exhaust Temp. (F) (C) 824 980 981 976 885 915 440 527 527 524 474 491
GT06543
15
Pressure Ratio 40:1 40:1 31.5:1 29.2:1 30.9:1 29.3:1 28.5:1 23:1 23:1 19.4:1 18.0:1 16.0:1 20.2:1 40:1 40:1 31.3:1 3,600 299 136 819 437 3,600 456 207 782 417 3,600 458 207.6 780 416 7,900 104 47 915 491 3,000 142 64 894 479 3,000 154 70 1001 538 3,000 168 76 927 497
GE Energys Oil & Gas products are installed in major upstream, midstream, downstream and distribution applications around the world.
Turbine Speed (rpm) 3,000 3,000 3,627 3,627 3,627 3,627 3,627 3,600 3,600 201 91 977 525 202 92 976 524 279 272 127 123 838 853 448 456 292 132 834 446 284 129 817 436 456 302 207 137 783 813 417 434 458 208 782 416
Exhaust Flow (lb/sec) (kg/sec)
Exhaust Temp. (F) (C)
LMS100PA 98,359 50,041 42,890 46,903 41,711 40,400 32,916 32,689 26,463 22,346 17,674 13,748 98,816 98,196 50,080 43,471 46,824 42,336 40,200 33,394 33,165 27,763 23,292 17,606 13,769 Output (hp) 59,355 45,740 45,417 31,164 24,146 19,105 8,896 7,872 7,986 10,283 10,315 10,158 9,148 9,391 9,369 8,833 8,915 8,725 8,621 7,873 8,925
98,894
7,979
LMS100PB LM6000PC Sprint*
LM6000PC
LM6000PD Sprint
LM6000PD LM6000PD (liquid fuel)
LM2500RC
50 Hz Power Gen
LM2500RD
LM2500PH
LM2000PE
S M A L L H E AV Y - D U T Y a n d A E R O D E R I VAT I V E G A S T U R B I N E S
LM2000PS
LM1600PE
LMS100PA
LMS100PB
LM6000PC Sprint*
LM6000PC
LM6000PD Sprint
LM6000PD
452
LM6000PD (liquid fuel)
LM2500RC
60 Hz Power Gen
LM2500RD
LM2500PH
LM2500PE
LM2000PS
LM1600PE
LM6000PC
LM2500RD
LM2500PE
LM2000PE
*Sprint 2002 deck is used with water injection to 25 ppmvd for power enhancement. NOTE: Performance based on 59F amb. Temp., 60% RH, sea level, no inlet/exhaust losses on gas fuel with no NOx media unless otherwise specified
Mechanical Drive
LM1600PE
PSP30305
LM2500RC
IGCC
GE GAS TURBINES FOR IGCC APPLICATIONS
Gas Turbines Model GE10 6B 7EA 9E 6FA 7FA 9FA 7FB 90 MW (50/60 Hz) 197 MW (60 Hz) 286 MW (50 Hz) 232 MW (60 Hz) 90 MW (60 Hz) 150 MW (50 Hz) 42 MW (50/60 Hz) 10 MW (50/60 Hz) GE10 106B 107EA 109E 106FA 107FA 109FA 207FB Syngas Power Rating Model IGCC Syngas CC Output Power 14 MW (50/60 Hz) 63 MW (50/60 Hz) 130 MW (60 Hz) 210 MW (50 Hz) 130 MW (50/60 Hz) 280 MW (60 Hz) 420 MW (50 Hz) 750 MW (60 Hz)
16
The Next Generation Power Plant
I G CC
Making Environmental Compliance Affordable
Integrated Gasification Combined Cycle (IGCC) technology is increasingly important in the world energy
market, where low cost opportunity feedstocks such as coal, heavy oils and pet coke are the fuels of choice.
And IGCC technology produces low cost electricity while meeting strict environmental regulations.
The IGCC gasification process cleans heavy fuels and converts them into high value fuel for gas turbines.
Pioneered by GE almost 30 years ago, IGCC technology can satisfy output requirements from 10 MW to
more than 1.5 GW and can be applied in almost any new or re-powering project where solid and heavy
fuels are available.
Optimal Performance
For each gasifier type and fuel, there are vast numbers of technical possibilities. Integrated Gasification
Combined Cycle (IGCC) systems can be optimized for each type of fuel as well as site and environmental
requirements. Using knowledge gained from successfully operating many IGCC units, GE has optimized
system configurations for all major gasifier types and all GE IGCC gas turbine models.
PSP30120
Experience
This 550 MW IGCC is located at the Saras oil refinery in Sardinia. The three GE 109E singleshaft combined cycle units have accumulated over 12,000 hours of syngas operation.
GE engages experts from throughout the gasification industry at both operating and research levels to
develop the most economical and reliable approaches to IGCC technology. Using the same combined cycle
technology for IGCC that we use for conventional systems, GE offers extensive experience and high levels
Cover Photo: PSP30502-03, Inside Cover Photos: RDC27191-05-05, PSP30502-01. Designed by GE Energy Creative Services.
of reliability.
GE Value
Industries Served:
GE a leading global supplier of power generation technology, energy services and management GEis Value
17
systems, with an installed base of power generation equipment in more than 120 countries.
GE is a leading global supplier of power generation technology, energy services and management
GE Energy provides innovative, technology-based products and service solutions across the full systems, with an installed base of power generation equipment in more than 120 countries. GE Energy
Commercial and industrial power generation Distributed power Energy management Oil & Gas Petrochemical Gas compression Commercial marine power
spectrum of the energy industry. products and service solutions across the full spectrum of the provides innovative, technology-based
energy industry.
Our people, products and services provide enhanced performance, competitive life cycle costs Industries Served: and continuous technological innovation with unmatched experience. Our Customer-Centric

approach, combined with Six Sigma quality methodology, assures that customer needs
Commercial and industrial power generation
are defined up front and that performance against customer expectations is measured and
Distributed power
managed every step of the way.
Energy management
Oil & Gas
Energy rentals
Petrochemical
Gas compression
Commercial marine power
Energy rentals
Our people, products and services provide enhanced performance, competitive life-cycle costs and
continuous technological innovation with unmatched experience. Our Customer-Centric approach,
combined with Six Sigma quality methodology, assures that customer needs are defined up front and
that performance against customer expectations is measured and managed every step of the way.
GE Energy
4200 Wildwood Parkway Atlanta, GA 30339
gepower.com
GEA 12985E (06/05)
GE Energy
GAS TURBINE AND COMBINED CYCLE PRODUCTS
GER-3935B
GE Power Systems
Power Systems for the 21st Century H Gas Turbine Combined-Cycles

R.K. Matta G.D. Mercer R.S. Tuthill GE Power Systems Schenectady, NY

Contents
Abstract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Background and Rationale for the H System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Conceptual Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 The Case for Steam Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 H Technology, Combined-Cycle System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 H Product Family and Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 System Strategy and Integration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 H Gas Turbine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Compressor Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Combustor Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Turbine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Gas Turbine Validation: Testing to Reduce Risk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Compressor Design Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Combustor Design Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Fuel Injection Design Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Turbine Design Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Gas Turbine Factory Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Validation Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
GE Power Systems GER-3935B (10/00)


ii

Abstract
This paper provides an overview of GEs H System technology and describes the intensive development work necessary to bring this revolutionary technology to commercial reality. In addition to describing the magnitude of performance improvement possible through use of H System technology, this paper discusses the technological milestones during the development of the first 9H (50 Hz) and 7H (60 Hz) gas turbines. To illustrate the methodical product development strategy used by GE, this paper discusses several technologies which are essential to the introduction of the H System. Also included herein are analyses of the series of comprehensive tests of materials, components and subsystems which necessarily preceded full-scale field testing of the H System. This paper validates one of the basic premises on which GE started the H System development program: Exhaustive and elaborate testing programs minimize risk at every step of this process, and increase the probability of success when the H System is introduced into commercial service. In 1995, GE, the world leader in gas turbine technology for over half a century, introduced its new generation of gas turbines. This H System technology is the first gas turbine ever to achieve the milestone of 60% fuel efficiency. Because fuel represents the largest individual expense of running a power plant, an efficiency increase of even a single percentage point can substantially reduce operating costs over the life of a typical gas-fired, combined-cycle plant in the 400 to 500 megawatt range. The H System is not simply a state-of-the-art gas turbine. It is an advanced, integrated, combined-cycle system every component of which is optimized for the highest level of performance. GE Power Systems GER-3935B (10/00)

The unique feature of an H technology, combined-cycle system is the integrated heat transfer system, which combines both the steam plant reheat process and gas turbine bucket and nozzle cooling. This feature allows the power generator to operate at a higher firing temperature, which in turn produces dramatic improvements in fuel-efficiency. The end result is generation of electricity at the lowest, most competitive price possible. Also, despite the higher firing temperature of the H System, combustion temperature is kept at levels that minimize emission production. GE has more than two million fired hours of experience in operating advanced technology gas turbines, more than three times the fired hours of competitors units combined. The H System design incorporates lessons learned from this experience with knowledge gleaned from operating GE aircraft engines. In addition, the 9H gas turbine is the first ever designed using Design for Six Sigma methodology, which maximizes reliability and availability throughout the entire design process. Both the 7H and 9H gas turbines will achieve the reliability levels of our F-class technology machines. GE has tested its H System gas turbine more thoroughly than any system previously introduced into commercial service. The H System gas turbine has undergone extensive design validation and component testing. Full-speed, noload testing (FSNL) of the 9H was achieved in May 1998 and pre-shipment testing was completed in November 1999. This H System will also undergo approximately a half-year of extensive demonstration and characterization testing at the launch site. Testing of the 7H began in December 1999, and full-speed, no-load testing was completed in February 2000. The 7H gas turbine will also be subjected to extensive demonstration and characterization testing at the launch site. 1

Background and Rationale for the H System
The use of gas turbines for power generation has been steadily increasing in popularity for more than five decades. Gas turbine cycles are inherently capable of higher power density, higher fuel efficiency, and lower emissions than the competing platforms. Gas turbine performance is driven by the firing temperature, which is directly related to specific output, and inversely related to fuel consumption per kW of output. This means that increases in firing temperature provide higher fuel efficiency (lower fuel consumption per kW of output) and, at the same time, higher specific output (more kW per pound of air passing through the turbine). The use of aircraft engine materials and cooling technology has allowed firing temperature for GEs industrial gas turbines to increase steadily. However, higher temperatures in the combustor also increase NOx production. In the Conceptual Design section of this paper, we describe how the GE H System solved the NOx problem, and is able to raise firing temperature by 200F / 110C over the current F class of gas turbines and hold the NOx emission levels at the initial F class levels. The General Electric Company is made up of a number of different businesses. The company has thrived and grown due, in part, to the rapid transfer of improved technology and business practices among these businesses. The primary technology transfer channel is the GE Corporate Research & Development (CR&D) Center located in Schenectady, NY. The H System new product introduction (NPI) team is also located in Schenectady, facilitating the efficient transfer of technology from CR&D to the NPI team. Formal technology councils, including, for instance, the Thermal Barrier Coatings Council, High Temperature Materials Council, and the Dry Low NOx (DLN) Combustion Council, also promote synergy among the businesses, fostering development of advanced technology. GE Power Systems (GEPS) and GE Aircraft Engines (GEAE) share many common links, including testing facilities for DLN, compressor components, and steam turbine components. In a move which could only have occurred within GE, with its unique in-house resources, over 200 engineers were transferred from GEAE and CR&D to GEPS, to support the development of the H System. These transfers became the core of the H Systems Design and Systems teams. H System technology is shared in its entirety between GEPS and GEAE, including test data and analytical codes. In contrast to the free exchange of core technical personnel between GEPS and GEAE, several of GEs competitors have been forced to purchase limited aircraft engine technology from outside companies. This approach results in the acquisition of a specific design with limited detail and flexibility, but with no understanding of the underlying core technology. In contrast, the transfer from GE Aircraft Engines to GEPS includes, but is not limited to, the following technologies, which are described later in the paper: Compressor aerodynamics, mechanical design and scale model rig testing Full-scale combustor testing at operating pressures and temperatures Turbine aerodynamics, heat transfer, and nozzle cascade testing Transfer of materials and coating data Processing for turbine blade and wheel superalloys


Gas turbine instrumentation application and monitoring. Technology contributed by CR&D includes: Development of heat transfer and fluid flow codes Process development for thermal barrier coatings Materials characterization and data Numerous special purpose component and subsystem tests Design and introduction of nondestructive evaluation techniques. stages. With the H Systems higher pressure ratio, the use of only three turbine stages would have increased the loading on each stage to a point where unacceptable reduction in stage efficiencies would result. By using four stages, the H turbine is able to specify optimum work loading for each stage and achieve high turbine efficiency.
The Case for Steam Cooling

The GE H System gas turbine uses closed-loop steam cooling of the turbine. This unique cooling system allows the turbine to fire at a higher temperature for increased performance, yet without increased combustion temperatures or their resulting increased emissions levels. It is this closed-loop steam cooling that enabled the combined-cycle GE H System to achieve 60% fuel efficiency while maintaining adherence to the strictest, low NOx standards (Figure 1).
Conceptual Design
The GE H System is a combined-cycle plant. The hot gases from the gas turbine exhaust proceed to a downstream boiler or heat recovery steam generator (HRSG). The resulting steam is passed through a steam turbine and the steam turbine output then augments that from the gas turbine. The output and efficiency of the steam turbines bottoming cycle is a function of the gas turbine exhaust temperature. For a given firing temperature class, 2600F / 1430C for the H System, the gas turbine exhaust temperature is largely determined by the work required to drive the compressor, that is, in turn, affected by the compressor pressure ratio. The H Systems pressure ratio of 23:1 was selected to optimize the combined-cycle performance, while at the same time allowing for an uncooled last-stage gas turbine bucket, consistent with past GEPS practice. The 23:1 compressor-pressure ratio, in turn, determined that using four turbine stages would provide the optimum performance and cost solution. This is a major change from the earlier F class gas turbines, which used a 15:1 compressor-pressure ratio and three turbine
Figure 1. Combustion and firing temperatures Combustion temperature must be as low as possible to establish low NOx emissions, while the firing temperature must be as high as possible for optimum cycle efficiency. The goal is to adequately cool the stage 1 nozzle, while minimizing the decrease in combustion product temperature as it passes through the stage 1 nozzle. This is achieved with closed-loop steam cooling.


In conventional gas turbines, with designs predating the H System, the stage 1 nozzle is cooled with compressor discharge air. This cooling process causes a temperature drop across the stage 1 nozzle of up to 280F/155C. In H System gas turbines, cooling the stage 1 nozzle with a closed-loop steam coolant reduces the temperature drop across that nozzle to less than 80F/44C (Figure 2). This results in a firing temperature class of 2600F/1430C, or 200F/110C higher than in preceding systems, yet with no increase in combustion temperature. An additional benefit of the H System is that while the steam cools the nozzle, it picks up heat for use in the steam turbine, transferring what was traditionally waste heat into usable output. The third advantage of closed-loop cooling is that it minimizes parasitic extraction enhances cycle performance by up to 2 points in efficiency, and significantly increases the gas turbine output, since all the compressor air can be channeled through the turbine flowpath to do useful work. A second advantage of replacing chargeable air with steam accrues to the H Systems cycle through recovery of the heat removed from the gas turbine in the bottoming cycle.
H Technology, Combined-Cycle System

The H technology, combined-cycle system consists of a gas turbine, a three-pressure-level HRSG and a reheat steam turbine. The features of the combined-cycle system, which include the coolant steam flow from the steam cycle to the gas turbine, are shown in Figure 3. The high-pressure steam from the HRSG is expanded through the steam turbine's high-pressure section. The exhaust steam from this turbine section is then split. One part is returned to the HRSG for reheating; the other is combined with intermediate-pressure (IP) steam and used for cooling in the gas turbine. Steam is used to cool the stationary and rotational parts of the gas turbine. In turn, the heat transferred from the gas turbine increases the steam temperature to approximately reheat temperature. The gas turbine cooling steam is returned to the steam cycle, where it is mixed with the reheated steam from the HRSG and introduced to the IP steam turbine section. Further details about the H combined-cycle system and its operation can be found in GER 3936A, Advanced Technology CombinedCycles and will not be repeated in this paper.
Advanced Open Loop Air-Cooled Nozzle
H SystemTM Closed-Loop Cooled Nozzle
AIR IN
AIR IN
STEAM IN
OUT
IN
STEAM OUT
NOZZLE DT = 280F/155C
NOZZLE DT = 80F/44C
Figure 2. Impact of stage 1 nozzle cooling method of compressor discharge air, thereby allowing more to flow to the head-end of the combustor for fuel premixing. In conventional gas turbines, compressor air is also used to cool rotational and stationary components downstream of the stage 1 nozzle in the turbine section. This air is traditional labeled as chargeable air, because it reduces cycle performance. In H System gas turbines, this chargeable air is replaced with steam, which
H Product Family and Performance

The H technology, with its higher pressure ratio and higher firing temperature design, will establish a new family of gas turbine products. The 9H and 7H combined-cycle specifications


One extremely attractive feature of the H technology, combined-cycle power plants is the high specific output. This permits compact plant designs with a reduced footprint when compared with conventional designs, and consequently, the potential for reduced plant capital costs (Figure 4). In a 60 Hz configuration, the H technologys compact design results in a 54% increase in output over the FA plants with an increase of just 10% in plant size. Figure 3. H Combined-cycle and steam description are compared in Tables 1 and 2 with the similar F technology family members. The 9H and 7H are not scaled geometrically to one another. This is a departure from past prac9FA Firing Temperature Class, F (C) Air Flow, lb/sec (kg/sec) Pressure Ratio Combined Cycle Net Output, MW Net Efficiency, % NOx (ppmvd at 15% O2) 9H 2400 (1316) 2600 (1430) 1376 (625) 15 391 56.7 25 1510 (685) 23 480 60 25
GE is moving forward concurrently with development of the 9H and 7H. However, in response to specific customer commitments, the 9H was
Table 1. H Technology performance characteristics (50 Hz)

7FA Firing Temperature Class, F (C) Air Flow, lb/sec (kg/sec) Pressure Ratio Combined Cycle Net Output, MW Net Efficiency, % NOx (ppmvd at 15% O2) 7H
2400 (1316) 2600 (1430) 953 (433) 15 263 56.0 9 1230 (558) 23 400 60 9
Figure 4. 7H and 7FA footprint comparison
Table 2. H Technology performance characteristics (60 Hz) tices within the industry, but has been driven by customer input to GE. The specified output of the H technology products is 400 MW at 60 Hz and 480 MW at 50 Hz in a single-shaft, combined-cycle system. The 9H has been introduced at 25 ppm NOx, based on global market needs and economics. GE Power Systems GER-3935B (10/00)

introduced first. The 7H program is following closely, about 12 months behind the 9H. The 7H development has made progress as part of the Advanced Turbine Systems program of the U.S. Department of Energy and its encouragement and support is gratefully acknowledged.
System Strategy and Integration

While component and subsystem validation is necessary and is the focus of most NPI pro5

grams, other factors must also be considered in creating a successful product. The gas turbine must operate as a system, combining the compressor, combustor and turbine at design point (baseload), at part load turndown conditions, and at no load. The power plant and all power island components must also operate at steady state and under transient conditions, from startup, to purge, to full speed. Unlike traditional combined-cycle units, the H System gas turbine, steam turbine and HRSG are linked into one, interdependent system. Clearly, the reasoning behind these GE H System components runs contrary to the traditional approach, which designs and specifies each component as a stand-alone entity. In the H System, the performance of the gas turbine, combined-cycle and balance of plant has been modeled, both steady state and transient; and analyzed in detail, as one large, integrated system, from its inception. The GE H System concept incorporates an integrated control system (ICS) to act as the glue, which ties all the subsystems together (Figure 5). Systems and controls teams, working closely with one another as well as with customers, have formulated improved hardware, software, and control concepts. This integration was facilitatControl Room Remote Dispatch
ed by a new, third-generation, full-authority digital system, the Mark VI controller. This control system was designed with and is supplied by GE Industrial Systems (GEIS), which is yet another GE business working closely with GEPS. The control system for the H System manages steam flows between the HRSG, steam turbine and gas turbine. It also schedules distribution of cooling steam to the gas turbine. A diagnostic capability is built into the control system, which also stores critical data in an electronic historian for easy retrieval and troubleshooting. The development of the Mark VI and integrated control system has been deliberately scheduled ahead of the H gas turbine to reduce the gas turbine risk. With the help of GE CR&D, the Mark VI followed a separate and rigorous NPI risk abatement procedure, which included proof of concept tests and shake down tests of a full combined-cycle plant at GE Aircraft Engines in Lynn, Massachusetts. The Systems and controls teams have state-ofthe-art computer simulations at their disposal to facilitate full engineering of control and fallback strategies. Digital simulations also serve as a training tool for new operators. Simulation capability was used in real time during the 9H Full-Speed No-Load (FSNL)-1 test in May 1998. This facilitated revision of the accelerating torque demand curves for the gas turbine and re-setting of the starter motor current and gas turbine combustor fuel schedule. The end result was an automated, one-button, softstart for the gas turbine, which was used by the TEPCO team to initiate the May 30, 1998 customer witness test. The balance of this paper will focus on the gas turbine and its associated development program.
Fault Tolerant Plant Data Highway
Color Display Printer
Log Printer
Operator Station
Operator Station
Engineering Workstation
Historian
Redundant Unit Data Highway HMI/ Server Steam Turbine & Bypass Control Gas Turbine & Cooling Steam Control
Generator Excitation & Protection
Static Starter
HRSG & Steam Cycle Mechanical Auxiliaries
Unit Auxiliary Control
HMI/ Server
Alarm Printer
HRSG/MA Gas Turbine Generator Steam Turbine BOP Equipment
All New Microprocessor Design Triple Modular Redundant Remotable I/O Capability for I/O Expansion Redundant Control and Plant Data Highways Peer-to-Peer Communications Time Synchronized Unit Controls Time Coherent System Data Integrated System Diagnostics Independent OS and OT Protection
Figure 5. Mark VI ICS design integrated with H Systems design


H Gas Turbine
The heart of the GE H System is the gas turbine. The challenges, design details, and validation program results follow. We start with a brief overview of the 9H and 7H gas turbine components (Figure 6). to control compressor airflow during turndown, as well as to optimize operation for variations in ambient temperature.
Combustor Overview
The H System can-annular combustion system is a lean pre-mix DLN-2.5 H System, similar to the GE DLN combustion systems in FA-class service today. Fourteen combustion chambers are used on the 9H, and twelve combustion chambers are used on the 7H. DLN combustion systems have demonstrated the ability to achieve low NOx levels in field service and are capable of meeting the firing temperature requirements of the GE H System gas turbine while obtaining single-digit (ppm) NOx and CO emissions.
Figure 6. Cross-section H gas turbine
Turbine Overview
The case for steam cooling was presented earlier under Conceptual Design. The GE H System gas turbines first two stages use closed-loop steam cooling, the third stage uses air cooling, while the fourth and last stage is uncooled. Closed-loop cooling eliminates the film cooling on the gas path side of the airfoil, and increases the temperature gradients through the airfoil walls. This method of cooling results in higher thermal stresses on the airfoil materials, and has led GEPS to use single-crystal super-alloys for the first stage, in conjunction with thin ceramic thermal barrier coatings (Figure 7). This is a combination that GEAE has employed in its jet engines for 20 years. GEPS reached into the extensive GEAE design, analysis, testing and production database and worked closely with GEAE, its supplier base, and CR&D to translate this experience into a reliable and effective feature of the H System gas turbine design. GE follows a rigorous system of design practices which the company has developed through hav-
Compressor Overview
The H compressor provides a 23:1 pressure ratio with 1510 lb/s (685 kg/s) and 1230 lb/s (558 kg/s) airflow for the 9H and 7H gas turbines, respectively. These units are derived from the high-pressure compressor GE Aircraft Engines (GEAE) used in the CF6-80C2 aircraft engine and the LM6000 aeroderivative gas turbine. For use in the H gas turbines, the CF6-80C2 compressor has been scaled up (2.6:1 for the MS7001H and 3.1:1 for the MS9001H) with four stages added to achieve the desired combination of airflow and pressure ratio. The CF6 compressor design has accumulated over 20 million hours of running experience, providing a solid design foundation for the H System gas turbine. In addition to the variable inlet guide vane (IGV), used on prior GE gas turbines to modulate airflow, the H compressors have variable stator vanes (VSV) at the front of the compressor. They are used, in conjunction with the IGV,


The systematic design and technology-validation approach described in this paper has proved to be the aerospace and aircraft industrys most reliable practice for introduction of complex, cutting-edge technology products. The approach is costly and time consuming, but is designed to deliver a robust product into the field for initial introduction. At its peak, the effort to develop and validate the H System required the employment of over 600 people and had annual expenses of over $100 million. Other suppliers perceive that design and construction of a full-scale prototype may be a faster development-and-design approach. However, it is difficult, if not impossible, for a prototype to explore the full operating process in a controlled fashion. For example, prototype testing limits the opportunity to evaluate alternative compressor stator gangs and to explore cause-and-effect among components when problems are encountered. The prototype approach also yields a much greater probability of failure during the initial field introduction of a product than does the comprehensive design approach, coupled with Six Sigma disciplines and the technology validation plan used by GE (Figure 8). The first phase in the H System development process was a thorough assessment of product options, corresponding design concepts, and system requirements. Also crucial in the first phase was careful selection of materials, components and subsystems. These were sorted into categories of existing capabilities or required technology advancements. All resources and technological capabilities of GEAE and CR&D were made available to the Power Systems Htechnology team. For each component and subsystem, risk was assessed and abatement analyses, testing, and
Figure 7. H Stage 1 nozzle and bucket single crystal ing a wide range of experiences with gas turbines in the last 20 years. For instance, GEAEs experience base of over 4000 parts indicates that thermal barrier coating on many airfoils is subject to loss early in operation, and that maximization of coating thickness is limited by deposits from environmental elements, evidenced by coating spallation when thickness limits are exceeded. Through laboratory analyses and experience-based data and knowledge, GE has created an airfoil that has shown, during field tests, that it maintains performance over a specific minimum cyclic life coatings, even with localized loss of coatings, as has been noted during field service.
Gas Turbine Validation: Testing to Reduce Risk

Although GEPS officially introduced the H System concept and two product lines, the 9H and 7H gas turbines, to the industry in 1995, H System technology has been under development since 1992. The development has been a joint effort among GEPS, GEAE, and CR&D, with encouragement and support from the U.S. Department of Energy, and has followed GEs comprehensive design and technology validation plan that will, when complete, have spanned 10 years from concept to power plant commissioning.


design process uses pitchline design and offdesign performance evaluation, axisymmetric streamline curvature calculations with empiricism for secondary flows and mixing, twodimensional inviscid blade-to-blade analysis and three dimensional viscous CFD blade row analysis. The aerodynamic design is iterated in concert with the aeromechanical design of the individual blade stages, optimizing on GEAE and GEPS experience-supported limits on blade loading, stage efficiency, surge margin, stress limits, etc. The program has completed the third and final compressor rig test at GEAEs Lynn, MA test facility. Tests are run with CF6 full-scale hardware, which amounts to a one-third scale test for the 9H and 7H gas turbines. Each rig test is expensive, approximately $20M, but provides validation and flexibility, significantly surpassing any other test options. The 7H rig test had over 800 sensors and accumulated over 150 hours to characterize the compressors aerodynamic and aeromechanical operations (Figure 9). Key test elements include optimum ganging of the variable guide vanes and stators; performance mapping to quantify airflow, efficiency, and stall margins; stage pressure and temperature splits; start-up, acceleration, and turndown character-
Advanced Technologies Needed
Design, Analysis & Component Tests
Proven Best Practices from Experience Base
23:1 Compressor Compressor Rig Tests Full pressure combustion tests Single crystal material Robust TBC coatings Steam Cooling Systems Nozzle cascade test Mark VI Control System
FSNL Factory Tests
FSFL Field Test
Inlet/Exhaust/Structures Through-Bolt Rotor Cold end drive PS & AE materials DLN combustion Proven analytical tools Proven production sources
Commercial Operation
GE Proprietary
H Event JAE 9
Figure 8. GE validation process data were specified. Plans to abate risk and facilitate design were arranged, funded, and executed. The second development phase covered product conceptual and preliminary designs, and included the introduction of knowledge gained through experience, materials data, and analytical codes from GEPS and GEAE. The H System development program is currently in its third and final phase, technology readiness demonstration. This phase includes execution of detailed design and product validation through component and gas turbine testing. A high degree of confidence has been gained through component and subsystem testing and validation of analysis codes. Completion of the development program results in full-scale gas turbine testing at our factory test stand in Greenville, SC, followed by combined-cycle power plant testing at the Baglan Energy Park launch site, in the United Kingdom.
Compressor Design Status

Modifications and proof-of-design are made through a rigorous design process that includes GEAE and GEPS experience-based analytical tools, component tests, compressor rig tests and instrumented product tests. The aerodynamic
Figure 9. 7H compressor test rig


istics; and identification of flutter and vibratory characteristics of the airfoils (aeromechanics). The three-test series has accomplished the following: Proof of concept, with four stages added to increase pressure ratio, and initial power generation operability completed August 1995. 9H compressor design validation and maps including tri-passage diffuser performance and rotor cooling proofof-concept completed August 1997. 7H compressor design validation completed August 1999, (Figure 10)
Cap Assembly
Swozzle Based Fuel Nozzle
Flowsleeve Impingement Sleeve
Combustion Liner
Transition Piece
Figure 11. Combustion system cross-section impingement holes for liner aft cooling. The liner cooling is of the turbolator type so that all available air can be allocated to the reaction zone to reduce NOx. Advanced 2-Cool composite wall convective cooling is utilized at the aft end of the liner. An effusion-cooled cap is utilized at the forward end of the combustion chamber.
Fuel Injector Design Status

The H System fuel injector is shown in Figure 12 and is based on the swozzle concept. The term swozzle is derived by joining the words swirler and nozzle. The premixing passage of the swozzle utilizes swirl vanes to impart rotation to the admitted airflow, and each of these swirl vanes also contains passages for injecting fuel into the premixer airflow. Thus, the premixer is very aerodynamic and highly resistant
Swirler Vanes Diffusion Swirler
Figure 10. Compressor map
Combustor Design Status

Figure 11 shows a cross-section of the combustion system. The technical approach features a tri-passage radial prediffuser which optimizes the airflow pressure distribution around the combustion chambers, a GTD222 transition piece with an advanced integral aft frame mounting arrangement, and impingement sleeve cooling of the transition piece. The transition piece seals are the advanced cloth variety for minimum leakage and maximum wear resistance. The flow sleeve incorporates
Premix Fuel Passages
Diffusion Gas Holes Uninterrupted Flowpath Diffusion Air Passage Inlet Flow Conditioner
Figure 12. Fuel injector system cross-section GE Power Systems GER-3935B (10/00)

10

to flashback and flameholding. Downstream of the swozzle vanes, the outer wall of the premixer is integral to the fuel injector to provide added flameholding resistance. Finally, for diffusion flame starting and low load operation, a swirl cup is provided in the center of each fuel injector. The H System combustor uses a simplified combustion mode staging scheme to achieve low emissions over the premixed load range while providing flexible and robust operation at other gas turbine loads. Figure 13 shows a schematic diagram of the staging scheme. The most significant attribute is that there are only The H System combustor was developed in an extensive test series to ensure low emissions, quiet combustion dynamics, ample flashback/ flameholding resistance, and rigorously assessed component lifing supported by a complete set of thermal data. In excess of thirty tests were run at the GEAE combustion test facility, in Evendale, OH, with full pressure, temperature, and airflow. Figure 14 shows typical NOx baseload emissions as a function of combustor exit temperature, and Figure 15 shows the comparable combustion dynamics data. The H components have significant margin in each case. In addition, hydrogen torch
PREMIXED MODE TURNDOWN PREMIXED MODE TURNDOWN (BASE LOAD VGV SIMULATION ) (BASELOAD VGV SIMULATION)
ISO NOx @ 15% O2 ppmvd.
Figure 13. Combustion mode staging scheme three combustion modes: diffusion, piloted premix, and full premix mode. These modes are supported by the presence of four fuel circuits: outer nozzle premixed fuel (P4), center nozzle premixed fuel (P1), burner quaternary premixed fuel (BQ), and diffusion fuel (D4). The gas turbine is started on D4, accelerated to FullSpeed No-Load (FSNL), and loaded further. At approximately 20-35% gas turbine load, two premixed fuel streams P1, and P4, are activated in the transfer into piloted premix. After loading the gas turbine to approximately 40-50% load, transfer to full premix mode is made and all D4 fuel flow is terminated while BQ fuel flow is activated. This very simplified staging strategy has major advantages for smooth unit operability and robustness. GE Power Systems GER-3935B (10/00)

Figure 14. NOx baseload emissions as a function of combustor exit temperature

PREMIXEDMODE MODE TURNDOWN PREMIXED TURNDOWN ( BASE LOADVGV VGV SIMULATION) SIMULATION ) (BASELOAD
Combustion Dynamics, Peak to Peak psida.
Figure 15. Comparable combustion dynamics data ignition testing was performed on the fuel injector premixing passages. In all cases the fuel injectors exhibited well in excess of 30 ft/s flameholding margin after the hydrogen torch 11
.dvmpp -2
Program Goal Program Goal Program Margined Goal Progam Margined Goal
O %51 @ xON OSI
T3.95 T3.95C -- degrees degrees FF c
.adisp -- kaeP ot kaeP ,scimanyD noitsubmoC
Discrete Peak Guideline Upper Limit

Discrete Peak Guideline Upper Limit
Overall Overall Level Level
Highest Peak HighestDiscrete Discrete Peak
T3.95 FF c degrees T3.95 -- degrees

C

was de-activated. In addition, lifing studies have shown expected combustion system component lives with short term Z-scores between 5.5 and 7.5 relative to the combustion inspection intervals on a thermal cycles to crack initiation basis. Thus, there is a 99.9% certainty that component lifing goals will be met. shows results for stage 1 nozzle internal cooling heat transfer. An extensive array of material tests has been performed to validate the material characteristics in a steam environment. Testing has included samples of base material and joints and the testing has addressed the following mechanisms: cyclic oxidation, fatigue crack propagation, creep, low-cycle fatigue and notched low-cycle fatigue (Figure 17).
Turbine Design Status

The turbine operates with high gas path temperatures, providing the work extraction to drive the compressor and generator. Two of the factors critical to reliable, long life are the turbine airfoil's heat transfer and material capabilities. When closed circuit steam cooling is used, as on the H turbine, the key factors do not change. However, the impact of steam on the airfoil's heat transfer and material capabilities must also be considered. For many years, the U.S. Department of Energy (DOE) Advanced Turbine System has provided cooperative support for GEs development of the H System turbine heat transfer materials capability and steam effects. Results have fully defined and validated the factors vital to successful turbine operation. A number of different heat transfer tests have been performed to fully characterize the heat transfer characteristics of the steam-cooled components. Figure 16
Figure 17. Materials validation testing in steam Thermal barrier coating (TBC) is used on the flowpath surfaces of the steam-cooled turbine airfoils. Life validation has been performed using both field trials (Figure 18) and laboratory analysis. The latter involved a test that duplicates thermal-mechanical conditions, which the TBC will experience on the H System airfoils. Long-term durability of the steam-cooled components is dependent on avoidance of internal deposit buildup, which is, in turn, dependent on steam purity. This is accomplished through system design and filtration of the gas turbine cooling steam. Long-term validation testing,
Figure 16. Full-scale stage 1 nozzle heat transfer test validates design and analysis predictions GE Power Systems GER-3935B (10/00)

Figure 18. Thermal barrier coating durability 12

currently underway at an existing power plant, has defined particle size distribution and validated long-term steam filtration. As further validation, specimens duplicating nozzle cooling passages have initiated long-term exposure tests. A separate rotational rig is being used for bucket validation. The H turbine airfoils have been designed using design data and validation test results for heat transfer, material capability and steam cooling effects. The durability of ceramic thermal barrier coatings has been demonstrated by three different component tests performed by CR&D: Furnace cycle test Jet engine thermal shock tests Electron beam thermal gradient testing The electron beam thermal gradient test was developed specifically for GEPS to accurately simulate the very high heat transfers and gradients representative of the H System gas turbine. Heat transfers and gradients representative of the H System gas turbine have also been proven by field testing of the enhanced coatings in E- and F-class gas turbines. The stage 1 nozzle, which is the H System component subjected to the highest operating temperatures and gradients, has been validated by another intensive component test. A nozzle cascade facility was designed and erected at GEAE (Figure 19). It features a turbine segment carrying two closed-loop steam-cooled nozzles downstream from a full-scale H System combustor and transition piece. This testing facility accurately provides the actual gas turbine operating environment. Two prototype nozzles complete with pre-spalled TBC were tested in April 1998. Data was obtained validating the aerodynamic design and heat transfer codes. Accelerated endurance test data was also GE Power Systems GER-3935B (10/00)

obtained. A second test series, with actual 9H production nozzles, is scheduled to start in the 4th quarter of 2000).
Figure 19. Nozzle cascade test facility The rotor steam delivery system delivers steam for cooling stage 1 and 2 turbine buckets. This steam delivery system relies on spoolies to deliver steam to the buckets without detrimental leakage, which would lead to performance loss and adverse thermal gradients within the rotor structure. The basic concept for power system steam sealing is derived from many years of successful application of spoolies in the GE CF6 and CFM56 aircraft engine families. In the conceptual design phase, material selection was made only after considering the effects of steam present in this application. Coatings to improve durability of the spoolie were also tested. These basic coupon tests and operational experience provided valuable information to the designers. In the preliminary design phase, parametric analysis was performed to optimize spoolie configuration. Component testing began for both air and steam systems. The spoolie was instrumented to validate the analysis. Again, the combination of analysis and validation tests provided confirmation that the design(s) under consideration were based on the right concept. 13

Over 50 component tests have been conducted on these spoolies, evaluating coatings, lateral loads, fits, axial motion, angular motion, temperature and surface finish. The detailed design phase focused on optimization of the physical features of the subsystem, spoolie-coating seat. In addition, refined analysis was performed to allow for plasticity lifecycle calculations in the region of the highest stresses. This analysis was again validated with a spoolie cyclic life test, which demonstrated effective sealing at machine operating conditions with a life over of 20,000 cycles. Spoolies were also used on the H System FSNL gas turbine tests. During the 9H FSNL-2 testing, compressor discharge air flowed through the circuit. This is typical of any no-load operation. Assembly and disassembly tooling and processes were developed. The spoolies were subjected to a similar environment with complete mechanical G loading. Post-testing condition of the seals was correlated to the observation made on the component tests. This provided another opportunity for validation. A rotating steam delivery rig (Figure 20) has been designed and manufactured to conduct cyclic endurance testing of the delivery system under any load environment. The rotating rig will subject components to the same centrifugal forces and thermal gradients that occur during actual operation of the turbine. This system testing will provide accelerated lifecycle testing. Leakage checks will be completed periodically to monitor sealing effectiveness. Test rig instrumentation will insure that the machine matches the operating environment. The rig has been installed in the test cell, and testing should resume in April 2000.
Gas Turbine Factory Tests

The first six years of the GE H System validation program focused on sub-component and component tests. Finally, in May 1998, the program moved on to the next stage, that of fullscale gas turbine testing at the Greenville, South Carolina factory (Figure 21). The 9H gas turbine achieved first fire and full speed and, then, over a space of five fired tests, accomplished the full set of objectives. These objectives included confirmation of rotor dynamics: vibration levels and onset of different modes; compressor airfoil aero-mechanics; compressor performance, including confirmation of airflow and efficiency scale-up effects vs. the CF6 scale rig tests; measurement of compressor and turbine rotor clearances; and demonstration of the gas turbine with the Mark VI control system. The testing also provided data on key systems:
Figure 20. Rotating rig installed in test stand GE Power Systems GER-3935B (10/00)

Figure 21. 9H gas turbine in half shell prior to first FSNL test 14

bearings, rotor cooling, cavity temperatures and effectiveness of the clearance control systems. Following the testing, the gas turbine was disassembled in the factory and measured and scrutinized for signs of wear and tear. The hardware was found to be in excellent condition. The 9H gas turbine was rebuilt with production turbine airfoils and pre-shipment tests performed in October and November 1999. This unit was fully instrumented for the field test to follow and, thus, incorporated over 3500 gauges and sensors (Figure 22). were once again demonstrated, and vibration levels were found to be acceptable without field balance weights. The Mark VI control system demonstrated full control of both the gas turbine and the new H System accessory and protection systems. The first 7H gas turbine was assembled and moved to the test stand in December 1999 (Figure 23). This 7H went through a test series similar to that for the first 9H factory test. However, the 7H not only covered the 9H test objectives described earlier, but also ran separately with deliberate unbalance at compressor and turbine ends to characterize the rotor sensitivity and vectors. The rotor vibrations showed excellent correlation with the rotor dynamic model and analysis. The 7H gas turbine is now back in the factory for disassembly and inspection, following the same sequence used for the 9H.
Figure 22. 9H gas turbine in test stand for pre-shipment test This second 9H test series took seven fired starts and verified that the gas turbine was ready to ship to the field for the final validation step. Many firsts were accomplished. The pre-shipment test confirmed that the rotating air/steam cooling system performed as modeled and designed. In particular, leakage, which is critical to the cooling and life of the turbine airfoils and the achievement of well-balanced and predictable rotor behaviors, was well under allowable limits. Compressor and turbine blade aeromechanics data were obtained at rates of up to 108% of the design speed, clearing the unit to run at design and over-speed conditions. Rotor dynamics
Figure 23. 7H gas turbine being installed in test stand
Validation Summary
GE is utilizing extensive design data and validation test programs to ensure that a reliable H System power plant is delivered to the customer. A successful baseline compressor test program has validated the H System compressor design approach. As a result of the 9H and 15


7H compressor tests, the H compressors have been fully validated for commercial service. The H turbine airfoils have been validated by extensive heat tests, materials testing in steam, TBC testing and steam purity tests. Test results have been integrated into detailed, threedimensional, aerodynamic, thermal and stress analysis. Full size verification of the stage 1 nozzle design is being achieved through the steamcooled nozzle cascade testing. Both 9H and 7H gas turbines have undergone successful factory testing and the 9H is now poised for shipment to the field and final validation test. and validation process. This ensures the highest probability of success, even before the product or shipping to customers and/or the product has begun operation in the field. The H technology, combined-cycle power plant creates an entirely new echelon of power generation systems. Its innovative cooling system allows a major increase in firing temperature, which allows the turbine to reach record levels of efficiency and specific work while retaining low emissions capability. The design for this next generation power generation system is now established. Both the 50 Hz and 60 Hz family members are currently in the production and final validation phase. The extensive component test validation program, already well underway, will ensure delivery of a highly reliable, combined-cycle power generation system to the customer.
Conclusion
The rigorous design and technology validation of the H System is an illustration of the GE NPI process in its entirety. It began with a well-reasoned concept that endured a rigorous review

16

List of Figures
Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Combustion and firing temperatures Impact of stage 1 nozzle cooling method H combined-cycle and system description 7H and 7FA footprint comparison Mark VI ICS design integrated with H System design Cross-section H gas turbine H Turbine - stage 1 nozzle and bucket single crystal GE validation process 7H compressor rig test Compressor map Combustion system cross-section Fuel injection system cross-section Combustion mode staging scheme Combustion test results NOx baseload emissions as a function of combustion exit temperature Combustion test results comparable combustion dynamics data Full-scale stage 1 nozzle complete band heat transfer test validates cooling design Materials validation testing in steam Thermal barrier coating durability Nozzle cascade test facility Rotating rig installed in test stand 9H gas turbine in half shell prior to first FSNL test 9H gas turbine in test stand for pre-shipment test 7H gas turbine being installed in test stand
List of Tables
Table 1. Table 2. H Technology performance characteristics (50 Hz) H Technology performance characteristics (60 Hz)

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Heavy Duty Output CC CC CC CC 280.3 MW 412.9 MW 50 Hz 60 Hz 400 MW 60 Hz 520 MW 50 Hz

MS9001H MS7001H MS9001FB MS7001FB

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50 Hz 60 Hz 50 Hz 60 Hz Small Heavy-Duty and Aeroderivative Gas Turbine Products Overview

6,281 6,281 9,315 9,340

6,627 6,627 9,830 9,855

IGCC (Integrated Gasification Combined Cycle) Overview

Worlds Most Advanced Combined Cycle Gas Turbine Technology

cost of electricity of this gas-fired power generation system.

Closed-Loop Steam Cooling

enabling lower emissions.

An MS9001H is seen during assembly in the factory.

Single Crystal Materials

up to high firing temperatures while meeting maintenance intervals.

Dry Low NOx Combustors

Small Footprint/High Power Density

nology with high customer confidence.

Worlds Most Experienced Advanced Technology Gas Turbines

cogenerators requiring large blocks of reliable power.

efficiencies, while maintaining reliability and availability.

An MS9001FA gas turbine ships from the plant.

FIRED HOURS IN THOUSANDS

7,794 6,859 5,790 4,899 4,186 3,575 2,989

MS7001FB and MS9001FB

Worlds Most Advanced Air-Cooled Gas Turbine

MS7001FB and MS9001FB

Hunterstown, PA 7FB launch site.

This MS7001FB is shown in the factory.

Net Plant Efficiency 58.0% 58.0% 57.3% 57.5%

GT Number & Type 1 x MS9001FB 2 x MS9001FB 1 x MS7001FB 2 x MS7001FB

MS7001FB and MS9001FB

per MBtu of natural gas burned.

MS6001FA, MS7001FA and MS9001FA

Proven Performance in a Mid-Size Package

Combined Cycle (IGCC).

can reach up to 46%.

Industry Standard for 60 Hz Power in All Duty Cycles

overall life cycle cost.

MS7001FA SIMPLE CYCLE PERFORMANCE RATINGS

tems and saving millions for our customers.

demand periodsincluding inlet cooling, steam injection, and peak firing.

efficiency, achieving less than 25 ppm NOx.

MS9001FA COMBINED CYCLE PERFORMANCE RATINGS

Proven Excellence in Reliable 50 Hz Combined Cycle Performance

achieving more than 52% efficiency in combined cycle.

achieve NOx emissions under 15 ppm when burning natural gas.

capacity expansion is required.

Time-Tested Performer for 60 Hz Applications

and is well recognized for high reliability and availability.