25 MW Gas Turbine MFT-8 for Compressor Driver

SATOSHI HATA* 1 HIROSHI FUKUI* 1 MASAHIRO KOBAYASHI* 1 OSAMU ISUMI* 1

Recently, energy conversion from petroleum to natural gas is being promoted, and plant constructions of gas pipe lines and gas fields are increasing globally. In plants having 25 MW class compressors, gas turbines are often used as compressor drivers. Against this background, Mitsubishi Heavy Industries, Ltd. (MHI) has modified its 25 MW gas turbine MFT-8, highly noted for marine propulsion and power generation use, for compressor driver, and evaluated the performance and reliability of the equipment in shop load test. As a result, the installation space of gas turbine is reduced by about 40% as compared with gas turbines of the same class of other manufacturers. In shop actual loading test, reliability of the equipment is confirmed, and at the rated load, the same high thermal efficiency as that of the original MFT-8 is confirmed, while in addition at partial load, sufficient practical performance is observed.
Table 1 shows the main characteristics of gas turbine MFT-8 for compressor driver. While maintaining the high thermal efficiency of the original MFT-8, it has been optimally modified for compressor driver. To be applicable to long-term continuous operation, which is an essential point as gas turbine for compressor driver, parts of the structure have been simplified from the original MFT-8 which has been developed because of the necessity for reduction of weight and quick starting as a marine propulsion engine.
Table 1 Specifications of MFT-8 for compressor driver Specifications Type Output Thermal efficiency Operating range Fuel type Power turbine lubricating oil (kW) (%) (min-1) Simple cycle 3-shaft 26 800* 38.7* 3 333 (70%) - 5 000 (105%) Natural gas fuel ISO-VG 32 (Mineral oil) Low pressure, axial flow, 8 stages High pressure, axial flow, 7 stages Cannular, 9 cans High pressure, axial flow, 1 stage Low pressure, axial flow, 2 stages Power turbine (PT) Axial flow, 3 stages GG8: ball-and-roller PT: tilting pad bearing (m) L 9.9 x W3.2 x H 3.5 Clockwise (view from compressor side)

1. Introduction
Recently, as energy conversion from petroleum to natural gas is being promoted, plant constructions of gas pipe lines and gas fields have been increasing globally. In plants having 25 MW class compressors, gas turbines are often used as drivers. MHI's 25 MW gas turbine MFT-8, which has been highly evaluated for marine propulsion and power generation use, has been newly modified for compressor driver, and its performance and reliability have been evaluated in shop load test.

2. Modification for compressor driver

Fig. 1 is a cross section of the modified gas turbine MFT-8 for compressor driver. This gas turbine is composed of a gas generator GG8 based on the aircraft engine of Pratt & Whitney Power Systems (PWPS), and a power turbine of MHI.
Exhaust

Compressor Gas generator Combustor GG 8 Structure Turbine

Inlet Power turbine

Gas generator (GG 8)

Bearing type Package dimensions Rotating direction

Fig. 1 Cross section of compressor driver MFT-8

* Values in ISO standard atmospheric condition, using gas fuel,

without inlet and exhaust loss, at shaft end.

*1 Hiroshima Machinery Works

Mitsubishi Heavy Industries, Ltd. Technical Review Vol. 41 No. 3 (Jun. 2004)

Principal changes are shown in Fig. 2 and Fig. 3 3. 2.1 Power turbine The power turbine of the original MFT-8 uses balland-roller bearings, and expensive synthetic oil is used as lubricating oil. For the compressor driver, the bearings of the power turbine are changed to tilting pad bearings, and mineral oil is used for lubrication, thus reducing the running cost.
Power turbine shaft (Hollow shaft Solid shaft)

Gas flow

As a result of the change of bearing type of the power turbine, the lubricating oil drain temperature is lowered by about 50 oC. The thermal stress generated in the exhaust frame around the bearing was tested by unsteady FEM analysis as shown in Fig. 4 and the reliability was 4, verified. In the stress concentrated portion of bearing supp o r t , i t s s t r e s s l e v e l w a s l o w, a n d i t h a s b e e n confirmed that there is no problem in low cycle fatigue strength. 2.2 Auxiliary equipment Major changes in the gas turbine are as follows. (1) Change of control method Fig. 5 shows a gas turbine operation screen, and Fig. Fig. 6 shows an monitoring screen for the gas turbine and compressor.

Journal and thrust bearings (Ball-and roller Tilting pad design) Fig. 2 Improvements to power turbine Added guide rail for maintenance Control devices

MFT-8 Start & Stop button

Exhaust Inlet

Fig. 5 MFT-8 control touch panel

Re-arrangement of piping route and auxiliary equipment Fig. 3 Improvements to auxiliary equipment

Power turbine casing High

Gas flow

Stress concentration portion

Low Bearing support Fig. 4 Unsteady thermal stress analysis

Stress level

Fig. 6 Monitoring screen for operation condition of MFT-8 gas turbine and compressor

Mitsubishi Heavy Industries, Ltd. Technical Review Vol. 41 No. 3 (Jun. 2004)

Oil console (for power turbine and compressor) Fire extinguishing equipment

Oil cooler

6 400

Inlet air silencer Inlet air filter

12 000

3 200

Ventilation filter

Exhaust silencer Cooler MFT-8 gas turbine

Oil console (for gas generator)

Ventilation fan

Compressor

GL 5 700

Ventilation damper 9 900 9 500

Fig. 7 Package arrangement of MFT-8

As the control device of gas generator of PWPS, Micronet of Woodward is used, while the PLC of AllenBradley is used as the control device of the power turbine of MHI. Further, by automating starting of the gas turbine main body and starting of the auxiliary machine, acceleration up to 70% of power turbine rotating speed (lowest speed in operation range 3 333 min-1) is realized in a single action. In deceleration, a function is provided for selecting the step-down method automatically depending on the cause of stop, and this is automated including stopping of auxiliary machine. (2) improvement to the enclosure structure Maintenance rails are provided in the enclosure, the engine can be removed without disassembly the enclosure, and easy maintenance is realized.

tion area is reduced by about 40% as compared with other manufacturers.

4. Load and performance test

A trial machine of MFT-8 for compressor driver was fabricated in accordance with these changes and modifications, and a shop load test was conducted for the purpose of evaluating the reliability and performance of the equipment. Fig. 8 shows an outline of the load test facility. A water dynamometer was used as the load device.

3. Comparison with other manufacturers

Fig. 7 shows the example of the typical arrangement of compressor train with Mitsubishi Advanced Compressor (MAC) and MFT-8 for compressor driver, and Table 2 able shows a comparison of gas turbine package dimensions of the same class from other manufacturers. The package is made compact by adjusting the piping route and equipment layout, and the package installaTable 2 Comparison of gas turbine package dimensions (Unit: m) MHI (MFT-8)
W=3.2

Exhaust duct and silencer

Ventilation duct and silencer

Inlet air duct and silencer

Ventilation fan

Water dynamometer

Manufacturer A
W=3.4

Manufacturer B
W=4.0
Oil console for GG 8

L=9.9

Installation area 32 m2

L=15.3 52 m2

L=12.8 51m2
Fig. 8 Outline of test equipment for MFT-8

Mitsubishi Heavy Industries, Ltd. Technical Review Vol. 41 No. 3 (Jun. 2004)

100
Power turbine bearing metal temp. ( C)

At 100% power turbine speed 95 90 85 80 75 70 65 60 55 50 20 000 Inactive side thrust bearing metal temp. Power turbine shaft vibration 21000 22 000 23 000 24 000 #2 journal bearing metal temp. Active side thrust bearing metal temp. #1 journal bearing metal temp.

100 90 80 70 60 50 40 30 20 10 0 25 000
Power turbine shaft vibration

Expected performance curve in ISO condition at100% speed (100% rotating speed: 4 762 rpm) 40 38
Thermal efficiency (%)

Expected performance curve in ISO condition at maximum continuous rotation (MCR) (MCR: 5 000 rpm)

36 34 32 30 28 26 24 22 20 15 000 Measurement points Test condition* : Expected performance curve in 100% speed (100% rotating speed: 4 762 rpm) *Test condition o Ambient temperature: 10 C Atmospheric pressure: 101.90 kPa Inlet loss: 90 mmAq Exhaust loss: 160 mmAq 20 000 25 000

Power turbine shaft end output (kW) Fig. 9 Measurement results of power turbine bearing metal temperature and shaft vibration

Power turbine shaft end output (kW) Fig. 10 Measurement results of power turbine performance

To confirm the reliability of the improved points of the power turbine, about 100 points were measured and the data were collected in real time. Fig. 9 shows the results of measurement of bearing metal temperature and shaft vibration at high load with power turbine 100% rotating speed. The metal temperatures of thrust bearings and journal bearings at rated load were, respectively, about 97oC and about 75oC, which fall within design allowable values, and reliability was confirmed. Shaft vibration at rated load was about 30 u m P-P, which was also within design allowable values. At other points, measurements were normal, which reliability of the equipment was verified. Fig. 10 shows the results of measurement of performance. It was confirmed that performances at the rated point and partial load were as planned. Thus, at the rated load, the high thermal efficiency of the original MFT-8 is maintained, and at partial load, sufficient practical performance could be confirmed.

5. Conclusions
MHI's 25 MW gas turbine MFT-8, in widespread use for marine propulsion and power generation purposes, has been modified for compressor driver. The controllability and maintainability have been improved accordingly, and the installation space of gas turbine is reduced by about 40% as compared with gas turbines of the same class made by other manufacturers. Reliability of the modified MFT-8 has been confirmed in shop load test. It was verified that the modified MFT8 has the same high thermal efficiency as the original MFT-8 at rated load, and has sufficient practical performance at partial load. In future, the product will be brought to the gas field market as a total package of Mitsubishi Advanced Compressor (MAC) and MFT-8 gas turbine.

Satoshi Hata

Hiroshi Fukui

Masahiro Kobayashi

Osamu Isumi

Mitsubishi Heavy Industries, Ltd. Technical Review Vol. 41 No. 3 (Jun. 2004)