GAS TURBINES

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Index
1. Basics of Gas Turbines.
2. Major Components of Gas Turbines.
3. Categories of Gas Turbines.
4. Performance Comparison of various makes of Gas Turbines.
5. GE’s range of Gas Turbines.
6. Factors affecting the performance of Gas turbines.
7. Gas Turbines at RIL.
8. Maintenance factors of Gas Turbines based on the fuel used.
9. The Hot gas path components & its metallurgy.
10. Gas Turbine Control Systems.
11. Performance Benchmarking.

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GAS TURBINE
A gas turbine, also called a combustion turbine, is a rotary
engine that extracts energy from a flow of combustion gas.
It has an upstream compressor coupled to a downstream
turbine, and a combustion chamber in-between.

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GAS TURBINE
By heating up compressed air, expanding it in nozzles
mechanical/rotational energy is obtained.

Buckets

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Brayton Cycle

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Ideal Brayton cycle:
•(1-2) Isentropic Compression - Ambient air is drawn into the compressor,
where it is pressurized.
• (2-3) Isobaric Process - The compressed air then runs through a combustion
chamber, where fuel is burned, heating that air—a constant-pressure process, since the
chamber is open to flow in and out.
•(3-4) Isentropic Expansion - The heated, pressurized air then gives up its
energy, expanding through a turbine (or series of turbines). Some of the work
extracted by the turbine is used to drive the compressor.
• (4-1) Isobaric Process - Heat Rejection (in the atmosphere).

Actual Brayton Cycle:

• Adiabatic process - Compression.
• Isobaric process - Heat Addition.
• Adiabatic process - Expansion.
• Isobaric process - Heat Rejection.

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GT Cutaway Showing Casing Cross Section

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 Simple Cycle Single Shaft Gas Turbine

• Compressor & Turbine are coupled to common single shaft.

•Normally used in process where less speed variation is
required.
• Due to larger rotor mass the speed can be easily kept
constant.
• Extremely suitable for generator drives.
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 Simple Cycle Two Shaft Gas Turbine

• In 2 shaft machines turbine is divided into High Pressure

(HP) turbine & Low Pressure (LP) turbine.
•HP turbine & compressor are attached to one shaft & LP
turbine is attached to another shaft.
• These machines provide wide speed range with sufficient
power & efficiency.
• Well suited for mechanical drives & compressors.
Open Cycle Gas Turbine Typical Performance
Combined Cycle Power Plant
Cogen Cycle Power Plant
• Gas Turbine Major
Components
Gas Turbine Major Components

Compressor

Turbine

Combustion chamber

Starting means
Gas Turbine Major Components

COMPRESSOR
• 17 stage axial flow compressor.
• Extractions 5th stage: bearing cooling and sealing air.
• 11th stage: Air bleed valves for surge control.
• 17th stage: Atom air compressor and pulse air.

TURBINE
• 3 Stage Impulse Turbine

COMBUSTION CHAMBER
• 10 combustors in annular space.
• 2 nos. Igniters in combustor no 1 & 10.
• 4 nos. Flame scanners in the combustor no 2,3 & 7,8.
Gas Turbine Major Components

GT ANNULAR FIRING CROSS FIRE TUBE

2+3+7+8 HAVE SCANNERS 1&10 HAVE IGNITORS

•Categories of Gas
Turbines
GAS TURBINE CATEGORIES
The Simple Gas Turbine is classified into five broad groups:

➢ Frame Type Heavy - Duty Gas Turbines: Large power generation units ranging
from 3 MW to 480 MW in a simple cycle configuration. Efficiency – 30 to 39 %.

➢Aircraft - Derivative Gas turbines: These are power generation units, which are
prime mover of aircraft in the aerospace industry. Efficiency – 35 to 45%.

➢Industrial Type - Gas Turbines: In the range of 2.5-15 MW. Used extensively
for compressor drive trains. Efficiency – Less than 30%.

➢Small Gas Turbines: In the range from about 0.5-2.5 MW. They often have
centrifugal compressors & radial inflow turbines. Efficiency – 15 to 25%.

➢ Micro - Turbines: In the range from 75 - 650 kW. Efficiency – 15 to 20%.

Frame Type Heavy - Duty Gas Turbines

Gas Turbines up to 20 MW.

Various Manufacturers are:

➢ Solar Turbine
➢ Rolls Royce
➢ Siemens
➢ MHI
➢ GE
Gas Turbine
Heat Turbine Exhaust
Output Efficiency Pressur Flow
MODEL Make Rate Speed Temp
(MW) % e (kg/sec)
(kcal/kwh) (rpm) (C)
Ratio
Saturn 20 Solar 1.2 3535 24.3 6.8 22516 6.55 504

501-KB5S Rolls Royce 3.897 2960 29.1 10.3 14200 15.4 560

SGT 100 Siemens 4.35 2865 30 13 16500 17.7 527

MF-61 MHI 5.925 3001 28.7 8.4 15400 27.3 496

Mars 100 Solar 10.69 2650 32.5 17.4 11168 42 488

LM1600PE GE 14.898 2544 33.8 21.3 7900 49.8 479

SGT 500 Siemens 17 2671 32.2 12 3000 92.5 375

Zorya
UGT-
Mashproe 20 2389 36 19.4 3000 72.2 412
15000
k t 20 of 119
+
Gas Turbine

Gas Turbines up to 60 MW.

Various Manufacturers are:

➢ Rolls Royce
➢ Siemens
➢ Alstom
➢ IHI
➢ Mitsubishi
Rolls Royce Gas Turbine
ISO BASE HEAT TURBINE EXHAUST
EFFICIENCY PRESS FLOW
MODEL YEAR RATING RATE
% RATIO (kg/sec)
SPEED TEMP
(MW) (kcal/kwh) (rpm) (Deg C)

RB211 6761 DLE 2000 32 2188 39.3 21.5 94.55 4850 503.33

TRENT 60 DLE 1996 51 2043 42 33 151.82 3000 444.44

TRENT 60 WLE 2001 58 2104 40 36 165.91 3000 423.33

Siemens Gas Turbine

ISO BASE HEAT TURBINE EXHAUST
EFFICIENCY PRESS FLOW
MODEL YEAR RATING RATE SPEED TEMP
% RATIO (kg/sec)
(MW) (kcal/kwh) (rpm) (Deg C)

SGT 700 1999 29.06 2389.72 36 18 91.36 6500 517.78

SGT 800 1998 45 2322.91 34 19.3 130.45 6600 1093.89
SGT 900 1982 49.5 2634.23 32.7 15.3 175.45 5425 513.89
IHI Gas Turbine

ISO BASE HEAT TURBINE EXHAUST

EFFICIENCY PRESS FLOW
MODEL YEAR RATING RATE SPEED TEMP
% RATIO (kg/sec)
(MW) (kcal/kwh) (rpm) (Deg C)

LM 6000
1997 46 2123.3 40.5 30 130.45 3000 445
PC SPRINT
LM 6000
1997 45.48 2123.5 40.5 30 130.91 3000 450
PD SPRINT

Mitsubishi Gas Turbine

ISO BASE HEAT TURBINE EXHAUST
EFFICIENCY PRESS FLOW
MODEL YEAR RATING RATE SPEED TEMP
% RATIO (kg/sec)
(MW) (kcal/kwh) (rpm) (Deg C)

MF221 1994 30 2689.69 32 15 108.18 7200 532.78

Gas Turbines more than 60 MW
Alstom Gas Turbine
ISO HEAT TURBINE EXHAUST
PRESS FLOW
MODEL YEAR BASE RATE EFFICIENCY SPEED TEMP
RATIO (kg/sec)
RATING (kcal/kwh) % (rpm) (Deg C)
(MW)
GT8C2 1998 56.3 2722 33.9 17 197 6219 508
GT11N2 1993 115.4 2559 33.6 16 400 3000 531
GT13E2 1993 172.2 2363 36.4 15 538 3000 522
GT26 1994 288 2246 38.3 32 633 3000 615
Ansaldo Energia
ISO HEAT TURBINE EXHAUST
EFFICIENCY PRESS FLOW
MODEL YEAR BASE RATE SPEED TEMP
% RATIO (kg/sec)
RATING (kcal/kwh) (rpm) (Deg C)
(MW)
V64.3A 1996 68.5 2364.51 34.7 15.8 191.4 3000 588.89

V 94.2 1981 166 2500.63 34.4 11.8 510.0 3000 546.11

V 94.3 A2 1995 272 2233.43 38.5 17.4 657.3 3000 575.00

V 94.3 A4 2004 279 2200.66 39.1 17.7 668.2 3000 577.22

Mitsubishi Gas Turbine

ISO BASE Eff Heat Rate Pressure Flow Turbine Exhaust
Model Type RATING % (kcal/kwh) Ratio (kg/sec) Speed Temp
(MW) (rpm) (Deg C)
M701 SC 144 34.8 2473 14 442 3000 542
M701F CC 273+142 59 1464 17 651 3000 600

M701G SC 334 39.5 2175 21 739 3000 587

Siemens Gas Turbine
HEAT
ISO TURBINE EXHAUST
RATE EFFICIENCY PRESS FLOW
MODEL YEAR BASE SPEED TEMP
(kcal/ % RATIO (kg/sec)
RATING (rpm) (Deg C)
kwh)
(MW)
SGT 1000F 1996 67.7 2452.74 35.1 15.8 191.82 5400 582.78
SGT 5 2000E 1981 163.3 2496.85 34.5 11.8 528.18 3000 542.22
SGT 6 3000E 1997 188.2 2359.47 36.5 13.4 520.00 3000 581.11
SGT 6 4000F 1995 278 2199.90 39 17.2 672.27 3000 582.22
SGT 5 3000E 1997 290 1509.03 54.9 (CC) 3000
SGT 5 4000F 1995 407 1434.97 57.7 (CC) 3000
GE’s range of Gas Turbines

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 GE Heavy Duty Gas Turbine
O/P Freq Kcal/
Model Type
(MW (Hz) kwh
The world demands a reliable supply )
of clean, dependable power. GE MS9001H CC 520 50 1434.3
offers a wide array of technological
options to meet the most challenging MS9001FB SC 412.9 50 1481.2

energy requirements. CC 390.8 50 1517.5

MS9001FA
SC 255.6 50 2331.7

CC 193.2 50 1656.2
MS9001E
SC 126.1 50 2546.0

CC 117.7 50 1573.0
MS6001FA
CC 75.9 50 2460.3

CC 64.3 50 1752.0
MS6001B
SC 42.1 50 2682.6

CC 67.2 50 1583.3
MS6001C
SC 45.4 50 2348.1
GE H-System

First gas turbine ever to achieve the milestone of

60%fuel efficiency.
 S 109H
109H System Combined Cycle Power Plant

➢ 520 MW; Single shaft.

➢ Firing Temperature Class: 1430˚C (2600˚F)
➢ Heat Rate: 1435 kcal/kwh.
➢ Efficiency: 60%
➢ 18 Stage Compressor; 23:1 Pressure Ratio; Airflow 687 kg/sec.
➢ NO x emissions: < 25 ppm.
➢ Steam Turbine: GE design; Reheat, Single flow exhaust.
➢ Generator: GE 550 MW LSTG; 660 MVA Liquid cooled.
➢ HRSG: 3 Pressure level reheat.
 The F Class Comparison
GE Siemens Alstom
(MS9001FA) (SGT5-4000F) (GT26)
SIMPLE CYCLE
Output 255.6 MW 278 MW 288 MW
Heat Rate 2332 kcal/kwh 2200 kcal/kwh 2246 kcal/kwh
Efficiency 36.90% 39.10% 38.3%
Pressure Ratio 17 17.2 32
Flow 642.2 kg/sec 672.2 kg/sec 633 kg/sec
Exhaust Temp. 602 Deg C 582 Deg C 615 Deg C

COMBINED CYCLE
Output 390.8 MW 407 MW 410 MW
Heat Rate 1517.5 kcal/kwh 1435 kcal/kwh 1488 kcal/kwh
Efficiency 56.70% 57.70% 57.8%
 H Class Comparison

GE Siemens
(S109H) (8000H)
Combined Cycle
Output 520 MW 530 MW
Heat Rate 1435 kcal/kwh 1435 kcal/kwh
Efficiency 60 % 60 %
Pressure
23 19.2
Ratio
Flow 687 kg/sec 820 kg/sec
GE Aero derivative Gas Turbine
 GE Aero derivative Gas Turbine
HEAT PRESSURE TURBINE
MODEL OUTPUT FLOW EXHAUST
RATE RATIO SPEED
(MW) (kg/sec) TEMP. (C)
(kcal/kwh) (rpm)

LMS100PA 102.998 1960.42 41.01 3000 213 407

LMS100PB 98.44 1906.48 40 3000 207 417

LM6000PC sprint 50 2132.85 31.5 3627 137 434

LM6000PC 42.89 2060.25 29.2 3627 129 436

LM6000PD sprint 46.9 2085.20 30.9 3627 132 446

LM6000PD 41.7 2110.92 29.3 3627 127 448

LM2500RC 32.91 2238.47 28.5 3600 92 524

LM2500RD 32.68 2243.76 23 3600 91 525

LM2500PH 26.46 2186.29 23 3000 76 497

GE 10 - 2 11.982 2557 15.5 11000 47 480

 Factors Affecting the
Gas Turbine Performance
Gas Turbine Performance
Influences on Gas Turbine Output:

➢ Compressor Fouling
➢ Size Influence
➢ Thermodynamic Influence
➢ Ambient condition Influence
➢ GT Speed
➢ Inlet & Exhaust Pressure Loss
Compressor Fouling

Fouling rate is a function of

➢ Environment
➢ Wind Direction
➢ Filtration System
Size Influence

Greater Dimensions

Higher Air flow

Higher Output
 Thermodynamic Influence

Mainly determined by the design of the

engine

➢ Main Component Efficiency

➢ Compressor Pressure Ratio
➢ Turbine Inlet Temperature

The combination of gas temperature and pressure ratio gives a specific

output, exhaust temperature and thermal efficiency, which also are
influenced by the components efficiency.
 Ambient Conditions Influence

Ambient Conditions Influence

➢ Ambient Air Pressure (P0)

➢ Ambient Air Temperature (T0)
➢ Ambient Air Relative Humidity (RH)

The gas turbine nominal performance is related to:

P = 1,013 bar
T = 15°C
RH = 60%
 Ambient Air Pressure (PO)

At constant gas temperature INCREASED ambient air pressure gives:

➢ Increased Output
➢ Unchanged Unit Efficiency

The air density reduces

as the site elevation
increases. While the
resulting airflow and
output decrease
proportionately,
the heat rate and other
cycle parameters are
not affected.
Ambient Air Temperature (TO)

The gas turbine is an air-breathing engine, its performance is changed

by Air Temperature that affects the density or mass flow of the air intake
to the compressor.

The following graph shows effect of Ambient Air temperature on

output, heat rate, heat consumption, and exhaust flow.
Ambient Air Relative Humidity
At constant gas temperature, INCREASED ambient air relative
humidity gives:

➢ Decreased Output

Humid air, which is less

dense than dry air, affects
output and heat rate, as
shown in Graph.
 GT Speed
Ref: GEperf.curve
GTF6SP
GT - MW change with speed at different ambient
temperature range

37
36 35.925 36 36.075 36.075
35.7
35 34.95
35.4

34 34.35
33.9 34.05 34.2 34.35
33.75 33.6
33 33.15 33.3
32.85 33.075 33.3 33.45
32.7 32.55
32 32.4
32.1 32.25 32.1 32.34 32.46
31.65 31.8
31 31.5 31.5 31.35 31.5
30.75 30.975 31.05 30.75 31.05
30.6
30 30
30.3
29.85
30.45
30
30.45
30
30.3
29.7
MW

29.625 29.55
29 29.1 29.4
28.875
29.4
29.025
29.325
28.8 28.65 28.65 28.65
28 28.35
27.975 28.2 28.2 27.975 28.35
27.6 27.6 27.75 27.6 27.6
27 27.225
26.85
27.15 27.15 27 27.3
26.475 26.7 26.55
26 26.1
26.4
26.025 26.1
25.65 25.575
25 25.35
24.975
25.35
24.9
24 24.3 24.6 24.3
23.925
23 23.55
23.175
22.8
22 22.125
21
20
95 96 97 98 99 100 101 102 103 104 105
speed %
5degC 15degC 20degC 25degC 30degC
35degC 40degC 45degC 50degC
Inlet & Exhaust Pressure Loss

Pressure Drop Effects for Frame - 6:

➢ 4 Inches H2O Inlet Drop Produces:

• 1.50%Power Output Loss

• 0.50 %Heat rate Increase
• 1.2 Deg F Exhaust temperature increase.

➢ 4 Inches H2O Exhaust Drop Produces:

• 0.50% Power Output Loss

• 0.50 %Heat rate Increase
• 1.2 Deg F Exhaust temperature increase.
Gas Turbines with
RELIANCE
RIL Gas Turbines
Heat Turbine Exhaust
Flow
MODEL Make Output Rate Efficiency Pressur Speed Temp
(kg/sec)
(MW) (kcal/kwh) % e (rpm) (0C)
Ratio
GE 10 - 2 GE 11.982 2557 33.3 15.5 11000 47 480

Fr - 5 GE 26.30 3022 28.5 10.5 5100 123 487.2

Fr - 6 GE 37.5 2752 32.1 12.2 5100 146 544

SGT 700 SIEMENS 29.06 2390 36 18 6500 91.36 518

LM6000PC GE 45.48 2123 40.5 30 3000 131 450

LM2500+ GE 30.057 2169 39.7 21.4 6100 84 500.5

GE 126.1 2548 33.8 (sc) 12.6 3000 418 543

Fr – 9E
GE 193.20 1656 52.0 (cc) 12.6 3000 418 543

GE 255.6 2334 36.9 (sc) 17 3000 642 602

Fr – 9 FA
GE 390.80 1517 56.7 (cc) 17 3000 641 602
Performance Curves for
Gas Turbine
Performance Curve for Gas Turbine

Power
Efficienc Firing
ISO Heat Flow consumed by
Model y Temp
Output Rate (lb/sec) Compressor
% (Deg C)
%
Fr – 5 26.3 3022 28.5 273 63.86 957

MS – 6541 37.5 2752 32.1 294.8 61.96 1104

Fr – 9E 126.1 2548 33.8 919.6 57.93 1124

Fr – 9FA 255.6 2334 36.9 1412.4 54.29 1327

Gas Turbine Compressor Power

NET
T1 T2 T3 T4 WORK TURBINE COMPRESSO
OUTPUT
(C) (C) (C) (C) RATIO
WORK R POWER %
(MW) (MW) (MW)

Fr - 5 26.3 15 315 957 487 0.361 73 46 63.86

MS-6541 37.5 15 362 1104 544 0.380 99 61 61.96

Fr-9E 126.1 15 340 1104 543 0.421 300 174 57.93

Fr-9FA 255.6 15 407 1327 605 0.457 559 304 54.29

LM600
45.48 15 535 1260 450 0.358 127 82 64.20
0 PC
SGT 700 29.06 15 416 1140 518 0.355 82 53 64.47
Effect of Power Consumed by Compressor

40 80

% POWER CONSUMED

THE COMPRESSOR
30 70
EFFICIENCY, %

BY
20 60

10 50

0 40
MODEL Fr - 5 MS-6541 Fr-9E Fr-9FA

Efficiency % %
Effect of Firing Temperature

40 1500

Firing Temp, Deg C

1250
30
Efficiency, %

1000

20 750

500
10
250

0 0
Model Fr - 5 MS-6541 Fr – 9E Fr - 9FA

Efficiency % Firing Temp (Deg C)

Comparison

Power Firing
ISO Heat Efficiency Flow
Model consumed by Temp
Output Rate % (lb/sec)
Compressor (Deg C)
%
MS-6541 37.5 2752 32.1 294.8 61.96 1104

Fr – 9FA 255.6 2334 36.9 1412.4 54.29 1327

• For every 100 Deg F/55.5 Deg C increase in firing temperature, the
efficiency increases about 1.5%. So, 223 Deg C rise in firing temp
increases the efficiency by 6%. Leading to improvement in heat rate by
165 kcal/kwh.
• 7 % reduction in compressor power consumption improves the heat rate
by 211 kcal/kwh.
• Remaining 2 %improvement in Heat rate as a result of:
▪ GTD-222 Stage 2 Nozzle
▪ Stage – 2 & 3 Honey Comb Shrouds
▪ 86i IGV setting
▪ Higher RPM Load Gear
▪ High Pressure Packing Brush Seal
▪ Improved Cooling Stage 1 Nozzle
• Approximately 20% of the Inlet Air to the Axial Flow
Compressor gets lost to the Thermal cycle due to losses
associated with cooling hot gas path parts or losses due to
Large Clearances.

• Most uprates on Gas Turbines typically are achieved by

Higher Airflow or Higher Firing Temperatures.
Maintenance Factors
of Gas Turbine
Combustion System Components
Efforts to advance the combustion system are driven by the need
for higher firing temperatures and for compliance with
regulatory requirements to reduce exhaust emissions.
Combustion System Components

Requirements:
➢ Withstanding Higher Firing Temperature.
➢ Low Emissions etc. NO x & CO.
➢ Life Time Extension.
➢ Maintenance Interval Extension.
Factors Affecting the Combustion Components Life

➢ Type of fuel
➢ Firing Temperature
➢ Cyclic Effects
➢ Steam or Water Injection Quality of Air
Maintenance factors – Hot gas path (Buckets & Nozzles)
Fuel vs. Component life

Estimated Effect of Fuel Type on Maintenance

 Fuel vs. Component life
Various fuels used are
RFG, Naphtha, HSD& LCO

. Liquid fuel High radiant energy

Impurities (Na, K, Va)

Results Thermal fatigue failure

Hot corrosion

1 hr of Liquid Fuel = 1.5 hrs of Gas Fuel

Operation Operation at Base Load
The Firing Temperature

Firing temperature Thermal efficiency

Power output

Results Creep
Distortion
Reduced life

1 hr of peak load = 6 hours of base load

operation. operation.
Cyclic Effects during Start/Stop
Cyclic Effects
➢Each stop and start of a gas turbine subjects the
hot gas path to significant thermal cycles.

➢Control systems are designed and adjusted to

minimize this effect.

➢The severity is phenomenal in the case of

emergency start and trips.

1 Emergency Trip = 8 Normal Shutdown Cycles

Steam or Water Injection
Steam or Water Injection

Steam or water is injected in to the combustion system

for:
• NO x Reduction
• Power Augmentation

This steam or water Injection used causes higher dynamic

pressure and due to higher specific heat capacity of steam
with respect to the gas, causes higher transfer of heat to
bucket and nozzle resulting in higher metal temperature of
these components reducing their life.
Hot Gas Path Components
&
its Metallurgy
Combustion Liners (FR1G/FR1H)
➢The original combustion liner was Louvered which was
cooled through louvered punches in liner body (Experiencing
cracking in punches during operation)
➢Replaced with a slot-cooled liner - provides a more uniform
distribution of cooling air flow for better overall cooling.
➢ Air enters the cooling holes, impinges on the brazed ring and
discharges from the internal slot as a continuous cooling film.
The Mechanism of Slot Cooled Liner

Advantage
• 139 C lower metal Temp.
• Lower Temp. gradient.
• Short length provide more stiffness and reduced cooling air.
 TBC Coated Liner
Advantage
•The 380 micron TBC thick provide 38 °C lower temp. in base metal.
• For firing temp. 1124 °C the thickness of liner is 15 mil thicker.
Transition piece Changes

• The Material Hastelloy-X replaced by Nimonic 263

because of superior to creep life time.
• The wall thickness is thicker and TBC coated.
• T.P was lengthened 15 in to relocate the wear of Liner-T.P
interface induced by compressor discharge air.
• Increasing inspection interval to 12000 E.O.H.
• Redesign of aft bracket allowing the T.P pivot during the
thermal cycling.
Turbine Components

There have been significant design and material

improvements made to the turbine components to improve
component designs which can withstand higher firing
temperatures due to advanced materials and coatings, as
well as the addition of air cooling for some of the
components.
BUCKETS
Stage 1 Bucket (FS2H)
Design
The original design’s sharp leading edge has
been blunted to allow more cooling air to flow
to the leading edge, which reduces thermal
gradients and cracks.
Materials
The original stage 1 bucket was IN- 738 is
changed to an Equiaxed (E/A) GTD-111, a
precipitation hardened, nickel-base super alloy,
a greater low cycle fatigue. It also provides the
industry standard in corrosion resistance.
Coatings
In 1997 the coating was changed again to GT-33
INCOAT. GT-33 is a vacuum plasma spray
coating, an increased resistance to through
cracking. “INCOAT” refers to an aluminide
coating on the cooling holes passages.
BUCKETS
Stage 2 Bucket (FS2F)
Cooling
The new stage 2 buckets contains
internal air cooling ,allows
for higher firing temperatures.
Tip Shroud
Shroud leading edge was scalloped
& tip was thickened & shroud
tapered. It resulted in 25%
reduction in stress and
80%increase in creep life.
Materials
The original bucket was made of U-700,
the material was changed to GTD-111,
also a precipitation-hardened, nickel-
Scalloping of bucket shroud base super alloy, to improve rupture
Coating strength. In addition it has higher low
GT 33 INCOAT cycle fatigue strength

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BUCKETS

Stage 3 Bucket (FS2K)

Design
The trailing edge was thickened, and the chord
length increased, the shroud leading edge was
scalloped, the shroud tip was thickened between
the seal teeth, and the underside of the shroud
was tapered. These design changes resulted in an
increase in creep life of the bucket.
Materials
The stage 3 bucket was originally made of U-500,
it was changed to IN-738, a precipitation
hardened, nickel-based super alloy.
Process Change
A new process for the bucket which eliminates
the need for the cold straightening step, thus
eliminating the process induced strain in the
material.

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NOZZLES
Stage 2 Nozzle (FS1P)

77 of 119
SHROUD BLOCKS

Stage 1 Shroud Blocks (FS2C)

The stage 1 shroud block was redesigned for the 2055°F/ 1124°C firing
temperature. The two piece design is film cooled using airflow from the stage 2
nozzle to inhibit cracking. The film cooling required additional flow which
translates into a performance loss. The main advantage of the two piece design
is that it allows the damaged caps to be replaced without Having to remove the
shroud block bodies or turbine nozzles. The body and hook fit are made of310
stainless steel and the cap is made of FSX-414.

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SHROUD BLOCKS
Stage 2 & 3 Shroud Honey Comb Seal
• Honey Comb Shroud:
i. Reduces Leakage
ii. Greater Rub Tolerance
• Requires Buckets with Cutter Teeth
• Provides a performance improvement up to 0.6% in both
output and heat rate.

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MATERIALS

Turbine Blades

Turbine Nozzles

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MATERIALS

Combustors

Turbine Wheels

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MATERIALS
Compressor Blades

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Improvement in Firing Temperature with
Blade Material

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Gas Turbine Control
Systems

84 of 119
 RIL Gas Turbine Control System

Due to non-availability of spares, Mark IV system at RIL sites are under proposal
for upgrade to Mark VI. Expected cost is Rs. 200 lacs per unit.

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 GE Control System Advances
System Type Mark I Mark II Mark II ITS Mark IV Mark V Mark VI

Introduced 1966 1973 1976 1982 1991 2004

Total Shipped 850 1825 356 1080 530 Ongoing

TMR TMR TMR

Sequencing Relays Discrete Solid State Components
Microprocessor Microprocessor Microprocessor

Discrete Solid TMR TMR TMR

Control ICs ICs & MPs
State Microprocessor Microprocessor Microprocessor

Relays & ICs & micro- TMR TMR TMR

Protection Relays
Solid State processor Microprocessor Microprocessor Microprocessor

Analog Meters
Analog and Digital Meters; Solid CRT & LED VGA VGA
Display & Relay
State Annunciator Aux. Display Color Graphics Color Graphics
Annunciator

Membrane Keyboard Keyboard

Input Push buttons and bat handled switches
Switches &/or CPD &/or CPD

SIFT, Software SIFT, Software

Fault Manually Rejects Failed Automatic Rejects Hardware
Implemented Implemented
Tolerance Exhaust Thermocouples Failed T/Cs. Based
Fault Tolerance Fault Tolerance

TMR & CRT Remote

Enhancement Integrated Circuits Micro-Processor SIFT, VGA Graphics
Display I/O capability

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 Introduction to Control Philosophy

Control system
Communicates with the turbine to
Measure, adjust the parameters

It also protects the turbine from abnormal operations

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 Introduction to Control Philosophy

Gas Turbine Controls

1. Basic Control Parameters of GT

2. Minimum Gate Concept of
Six Control Loop

▪ Start up
▪ Speed/Load Main
▪ Temperature
▪ Acceleration
▪ Manual Auxiliary

▪ Shut down

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 NAP/KER
UNIT CONTROL DISPLAY
HSD

EXHAUST BREAKER OPEN

84 dga
IGV
CRANK GEAR GENERATOR
WATTS
MOTOR
BOX VARS
PF
CPD FREQ
AIR INLET 8.55 barg Max. Vib
7.0 mm/sec
NORMAL RUN STATUS Master Master Load Fuel
SELECT2 PRESEL Select Control Control Select
STATUS_FLD UNLOADING
FSER_CONTROL SPEED-DROOP OFF BASE
START GAS
SPEED_LVL 14HS LOAD
FLAME # A# B # C # D CRANK FAST 100
GT_SPEED 98.75 % PRESEL HSD
START
TNR 102.57 % FIRE 75
SPREAD_1 30 deg C MW
FSR 64 %
STOP NAP
AUTO SETPOINT 50
MSG_FLD1 SIMPLE CYCLE
MSG_FLD2 IGV FULL OPEN LOAD CONTROL 25
SC43 AUTO CO-GEN DROOP
SC43F NAPTHA RAISE LOWER 0
LIQUID FUEL 100 %RT NAP/KER LUBE OIL
SIMPLE ISOCH

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Controlling and Monitoring
Stage Link
BOI
Mark-V
Panel Backup operator
Interface

<I> Station
Turbine Generator

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MARK-V CONTROL PANEL LAYOUT

<I>
Station

<S> <R> <C>

<T> < P> < PD >

IONET
DENET < QD1 > < CD >
POWER
STAGE LINK

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The MARK-V Control System Description

• The Mark-V control system has TMR (Triple Modular

Redundant) configuration.
▪ <R>, <S> and <T> control processor.
▪ <C> communication processor.
▪ <P> protective processor.
▪ <PD> power distribution processor.
▪ <QD1> & <CD> input & output processor.
▪ The < I > station is used to control the turbine.
▪ The <BOI> may be used to control the Turbine, whenever loss
of communication between the < I > station and Mark-V panel.

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Simple Cycle Package Power Plant Starting Time

* Time is in Minutes

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Gas Turbine Generator Controls & Limit

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Dual Fuel transfer Characteristics- Gas to Liquid

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Gas Turbine Fuel Control

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Gas Fuel Control System

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Liquid Fuel Control System

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Typical Gas Turbine Starting Characteristics

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 Exhaust Temperature Control

Temperature Controller ensures

that the Turbine internals
are protected from over
heat and Optimum power
is produced.

The firing temperature is difficult to

measure and hence the Controller
uses the exhaust thermocouples
as reference which is directly proportional to
Firing Temperature.

Tf = Tx (Pcd/Pa) k

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 Exhaust/Firing Temperature Relation

Curve comparing the load

at different ambient.

The firing temperature remains constant even with increase in MW, FSR & CPR
ratio with less exhaust temperatures.

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Acceleration Control

0.35 %/sec

0.10 %/sec
0% 40% 50% 75% 95%
100% TNH

Acceleration Control functions during sudden Load Changes and Start Up

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Manual Control

Manual Control Loop Can be used to limit fuel to prevent over firing
and over riding active control.

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 Shut Down Control

Shut down control loop reduces

the fuel at a predetermined
during shut down to reduce
thermal stresses.

FSRSD is the minimum of Six Control Loops

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 IGV Control

IGV Control Loop

• Controls air fuel ratio
• Prevents Compressor Pulsations

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 IGV Control

IGV scheduling is required

to ensure the protection from
Pulsation/Stall by
excessive opening
at lower speeds/loads and
negative pressures
at partial loads by less opening

IGV Schedule

Maintains higher Exhaust Temperature at partial loads for Combined Cycle Operation

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 IGV Control
Isothermal

The exhaust temp. varies

for simple and combined cycle
operations.
IGV temperature control never
exceeds the base temperature control
set point.

CPD

IGV control reference

Maintains higher Exhaust Temperature at partial loads for Combined Cycle Operation

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Performance Benchmarking

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 Purpose of Benchmarking

• Gives feed back on relative performance.

• Indicating opportunities for improvement.
• Un-earth and explore the outstanding Reliability issues.
• Highlight the areas for improvement.
• Target the initiatives for sustainable development.

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 Gas Turbine Key Performance Indicators
%Reliability accounting for
- No. of Emergency trips
- No. of Forced shutdowns
- No. of Unplanned shutdowns hrs
%Availability accounting for
- Outage duration
- MTBF
Key performance indicators
- Heat rate (Open cycle/Co-gen)
- Efficiency (Open cycle/Co-gen)
- Fuel efficiency improvement Index
Fuel , Power , Steam Costs & Grid Power Bill
- Percentage increase in Grid Power Consumption
- Fuel, Power & Steam Cost
- Fuel & Grid Power Bill

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Benchmarking at a Glance

• Number of Emergency Trips

• Number of forced shutdowns

– These are numbers which indicate the number of

equipment trips in each category.
– RIL benchmark for not more than 1 trip/year for
one equipment.

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Benchmarking at a Glance

• Number of unplanned shut down hours

– This is number which indicates the number of unplanned

shutdown hours in each category.

– RIL has a systematic budget approach targeting planned

shutdown hours for all the equipment.

– The Down time hours include planned and unplanned

shutdown hours.

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Benchmarking at a Glance

• GT open cycle heat rate

Total direct fuel fired in GT in Kcal
Power generated from GT in kwh

• GT/HRSG Co-gen Efficiency

➢ GT/HRSG Co-gen efficiency = ((A+B)/(C+D))*100
where
• A= GT power generation in thermal units
• B= HRSG steam generation in thermal units
• C= Fuel input to GT in thermal units
• D= Fuel input to HRSG supp firing in thermal units

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Benchmarking at a Glance

STG Cycle Efficiency

➢ This is the efficiency in % for STG.

➢ STG Efficiency = (A+B/C)*100

where
• A = ST power generation in thermal units
• B = Steam generation in thermal units
• C = Steam energy input at Steam turbine inlet in
thermal units

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Benchmarking at a Glance

Auxiliary Boiler Thermal Efficiency

➢ This is the efficiency in % for Auxiliary Boiler.

➢ Aux Boiler Efficiency = (A/B)*100

where
• A = Aux boiler steam generation in thermal units
• B = Fuel energy input to boilers in thermal units

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Benchmarking at a Glance

• Overall fuel utilization efficiency

– This is the combined efficiency of the CPP in %

– Overall Fuel utilization efficiency =((A+B+C)/(D+E+F))*100

• where
• A= GT power generation in thermal units
• B= ST power generation in thermal units
• C= Steam extraction+PRDS steam energy in thermal units
• D= GT input fuel in thermal units
• E= HRSG input suppl. fuel in thermal units
• F=Aux boiler input fuel in thermal units

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Benchmarking at a Glance

• Fuel efficiency improvement index

– This is the number in %, that indicates fuel efficiency
improvement to reference period.

• Fuel efficiency improvement index is then = A / B

where
A = Fuel efficiency for the current period
B = Fuel efficiency for the reference period overall

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 RIL - CPP Benchmarking Criteria

Based on Key performance indicators, Ranking allotted to plants

Sr. No. 2008-’09 2007-’08 2006-’07

1 Jamnagar Baroda Patalganga
2 Hazira Hazira Jamnagar
3 Nagothane Jamnagar Hazira
4 Baroda Nagothane Gandhar
5 Gandhar Gandhar Baroda
6 Patalganga Patalganga Nagothane

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 30 June 09

Thank
You