eal see eae) to} Nad INTERNATIONAL TLE TTC The Global Journal of Energy Equipment SA ieee ute eRe - eels asPOWER GENERATION Turkish plant launches GE turbine THE FRAME 6C TARGETS COMBINED CYCLE AND COGENERATION MARKETS. KALyay KALANARAMAN ‘emalpasa power plant — the launch site of GE's Frame 6C gas turbine in Izmir, Turkey started commercial combined cycle operation in November (Figure 1). Site work began on the 206C plant in January 2004 and start up a year later, with one of the two lead gas turbine units being instrumented to collect data, Instrumented operation till August which included full-load testing, complet ed design validation of this new gas tur- bine, according to GE. The Frame 6C incorporates technolo- gies that have been used in F class gas tute bines, as well as the 9H gas turbine and GE's aireraft engines. The gas turbine builds on the 6B machine that has logged cover 40 million hours of service worldwide. and 54% efficiency (Table). Plant layout Forecasting higher gas prices, GE started developing this high-efficiency successor to OB in carly 2000, Frederic Delaval, GE’s product line manager for the 6C machine, says, “The four percentage point improvement in efficiency over 6B ‘means thatthe 6C will have a lower lie- cyele cost than its older cousin if gas Prices are over about $2 per MMBtu depending on project species” While the 6C fitted with the GE Dry Low NO, (DLN2.5) system is designed for natural gas operation, with the possi- bility of distllated oil backup as in Kemalpasa, the 6B can handle « wider range of fuels, Target markets for the 6C are mainly combined cycle, industrial cogeneration or hydrid combined cycle- cogeneration systems primarily in Europe followed by Asia. The 6C is ideal for Independent Power Producers (IPP) and users with process needs, adds Delaval. The lzmit plant is owned by Akenerj, a leading Turkish IPP with an installed capacity of S40 MW and a pio- neer in gas turbine plants in the nation. ‘The two MS60001Cs in Kemalpasa are installed outdoors, and the generators are installed in the cold-end through a reduc- tion gear (Chart), Unlike the 6B, the 6C fol lows the F class units’ modular constuction using pre-assembled packages. The Gas Turbines (GTs) are arranged in a mle 6 Ttoractiney hamsters +NoxerbeDeconber 205 Figure 1: The Kemalpasa power plant is owned by Akeneri turbine pioneer in Turkey shaft arrangement with a GE steam turbine, installed in a separate building. h of the GTs has a Static Frequency Converter for starting, and is provided with self-cleaning air filters. ‘The 6C can come with a diesel generator for black start, if customers require it ‘The usual starting mode of the 6B is a diesel motor, The gas turbines are cooled by fin-fan coolers during open and combined cycle operation. Each GT has its associated Heat Recovery Steam Generator (HRSG), bypass stack and hydraulic- operated damper for open cycle, leading private producer and gas The factory-assembled steam turbine is enclosed in a single casing and exhausts axially to an air-cooled con- denser. The condenser is designed 10 maintain 70 mbar abs at steam turbine exhaust at an ambient air temperature of 16.3°C. Because the plant will be oper: ed in base-load mode, sparging steam not provided to the condenser. This steam is generally used for deaeration of con- densate water during start-up and low- load operation, A 10 barg auxiliary steam feeds the steam turbine glands during startup. This comes from High Pressure (HP) steam 268 ne conioning rst pe: nar gs oss power: 138.9 MY — 4 lambont conan: (Gross het ate (LM) 6,848.3 bk Jaavoncricpressre 0.9900 bara Gros pant efor (Li) 52.57% ar temperate ieae sate hamaty Chart: The 206C configuration in Kemalpasa offers over 118 MW and 52% efficiency at base loadFigure 2: The 12 stage compressor soction has Inputs from GE Oil & Gas and Aircraft Engines divisions when at least one HRSG is in service. HP steam flowing from both the HRSGs is mixed in a common header before admission into the steam turbine. Nominal HP steam inlet conditions are 36.2 bar abs, 536.7°C, and the nominal exhaust pressure is 70 mbar abs. The steam turbine and its generator are cooled by a closed water-to-air circuit dedicated to the steam and water loop. The height of the last stage blades is 660 mm. The generators of the gas turbines are GE 6A8 type with open air cooling and static air filters. The generator of the steam turbine is of the GE 6A type with water cooling, The HRSGs (stack height 30m) are of the two-pressure, natural-circulation type and are horizontally installed. A bypass stack at each HRSG inlet allows simple cycle operation. There are no stack closure dampers at the exhaust in this base-load plant The nominal characteristics at the HRSG are: + HP steam flow of 57.6 Uh, pressure of 58.1 bar abs, temperature 537.8°C + LP steam flow of 8.2 h, pressure of 4.4 bar abs, temperature 203,2°C Environmental conditions at the site include a maximum ambient air tempera- ture of 40°C, minimum ambient tempera- ture of =10°C, and a design ambient of slightly over 16°C at which the combined cycle net output and heat rate with natur- al gas and distillate fuel are guaranteed. The site grade elevation is 200 m. Kemalpasa gets its main fuel of natur- al gas from Botas, the Turkish national as company. The combined cycle plant also has distillate backup, The plant has been designed for base- load capability with about 50 startups per year. The maximum noise level at | m of MS6001B MS6007C Frequency (Hz) BOO ‘BOTED Rotating speed (rpm) 5,163 7,100 Pressure ratio (2a 791 Firing temperature (Cy 7140 1,327 Exhaust flow (UR) 325 2 Exhaust temp (Cy 552 574 ‘Simple cycle output (MW) an7 WS ‘Simple cycle efficiency (a) aig 36S ‘Combined cycle output (MW) 130.7 26.7 yombined cyole efficiency (%) 48 Baa NO, (ppmvd, 15% Op) 1S 1S Table: The efficiency of the Frame GC is four percentage polnts higher than the 6B Figure 3: Each combustion chamber can be removed quickly through ‘manholes without removing the main pipework, turbine shells or parts each module is guaranteed to be lower than 85 dBA. GE adds that the 6C can be offered for less than 80 dBA. While emis- sion limits at Kemalpasa are guaranteed at 25 ppm NO, with natural gas, GE says the 6C can achieve less than 15 ppm NO, and 9 ppm CO from base load to 50% load. Why Turkey? The Turkish economy is set to grow at an average of 8-9% in the next five years, The country is making efforts to join the European Union (EU) and reach EU stan- dards in many areas, including power consumption. And GE predicts that the country needs to add 20 GW of new capacity if it were to equal the per capita power consumption of Poland, a recent entrant to EU. Out of this new capacity, over 5 GW could come from gas turbines, Total natural gas consumption had increased to 750 bef in 2003, 400% higher than 1991. The power sector con- sumed 65% of this. Gas is imported from Russia through a land pipeline and an underwater pipeline in the Black Sea called “Blue Stream.” Completed in 2002, Blue Stream connects the Russian Port of Tuapse to the Turkish coastal city of Samsun. Turkey is expected to become a con- duit for gas from the Caspian Sea region, where new projects are expected to produce a total of nearly 6 Tef of gas/year. In March 2002 Turkey and Greece signed a memorandum of under- standing to build a $300. million pipeline linking the two countries, allowing Caspian Sea natural gas to reach European Union consumers. Further, Russia is expected to buy Caspian gas and re-export it to Turkey via the Blue Stream pipeline In January 2002, Iran and Turkey waugurated a natural gas pipeline link between Tebriz (northern Iran) and Ankara. Exports of Iranian natural gas toFigure 4: There are 60 buckets each on stage 41 & 2 and 90 on stage 3 ofthe turbine Turkey are expected to reach 350 Bef per year by 2007 GE also sees potential for cogeneration in Turkey, where steam is being sold at $20/ton. A. 130 MW cogeneration plant developed by Camis Plektrik Uretim A.S —a private power producer — will stat operation in 2006 at a soda ash factory in Mersin, Based on the Frame 9E, the plant will produce 380 tons of steam. With demand for gas increasing, gas prices have doubled in the last ten years, from around $130/1,000 cubic meters t0 nearly $250/1,000 cubic meters, Since Figure 5: Unlike other GE Energy designs, the ‘second stage bucket uses an unshrouded, serpentine-cooled design 2002, the Turkish government has made it easier for private producers to acquire licenses and set up power generation plants, and enter into bilateral contracts with “eligible consumers” — those that consume more than 9 million kWh per ‘year. But power prices are still fixed by the government, not the market. In spite of increasing gas prices, the ‘Turkish govemment is keeping power prices stable at 2002 levels. This has led to deci ing operating margins for private power pro- ducers, says Olcayto Yigit, regional sales ‘manager of GE. This has dampened inves ment in gas-fired generation, For instance, Akenerji, the owner of Kemalpasa, is planning to set up new combined cycle plants of 700-800 MW after power prices are determined by the free market, says Onder Karaduman. He ‘adds that because of the lower operating margins it has become important to have efficient power plants that reduce genera- tion costs, In 2002 Karaduman leamed about the 6C turbine. And Akenerji required GE to install the entire power island for Kemalpasa instead of buying only the equipment and installing it with the help of a contractor, Turbine features The three-stage 6C turbine incorporates ‘many features from the F and F class tur- bines (Figure 2). The turbine assembly is 4 traditional through-bolted.configura- tion, and consists ofa forward shaft, three turbine wheels (60 buckets each on stages 1 & 2, 90 buckets on stage 3), three tu bine spacer wheels and an aft turbine shaft, which includes the number 2 bear- ing journal (Figure 4), Cooling air is delivered to the turbine rotor through two paths. The first path delivers compressor discharge air from the discharge casing to the stage one buckets via an inducer. The second cooling air path to the rotor bleeds ar fom the eighth stageFigure 6: The compressor rotor (pressure ratio 19:1) includes a forward stub shaft carrying three blade rows, thirteen blade and wheel assemblies, and an aft stub shaft ‘of the compressor and delivers it down the center of the rotor to the turbine whee! spaces, and to the stage-two buckets via radial slots in the spacer between the first and second stage wheels, ‘The hot gas path components are mod- led on the 7FB using technology from the GE9O and the CFMS6 aireraft engines. ‘The stage-one vane is a singlet configura- tion cast from Equiax GTD-111. The air- {oil is cooled with a conventional two- chamber design using sheet metal inserts for backside impingement and film cool- ing, which subsequently feeds the film array, The endwalls are also cooled using backside impingement and film cooling, The stage-one bucket is east from sin- le crystal RENE NS, and uses a serpen- tine design much like that of the 7FB and the GE90. The stage-two vane is a dou- blet configuration and uses impingement to cool the outer band and airfoil, and a trailing edge bleed for convection cooling in the aft portion of the airfoil, The stage-two bucket is a significant departure from standard GE Energy tur- bine design philosophy. Unlike other designs, the MS6001C uses an unshroud- ced, serpentine-cooled, second-stage buck- ct, which GE says leads to a more uniform femperature distribution in the airfoil and reduces the bucket count (Figure 5). The third stage bucket uses a shrouded airfoil asin other E and F class turbines, The DLN.2.5H combustion system is a can-annular design with six cans linked together using cross-fire tubes. Each combustion chamber can be removed quickly through manholes without removing the main pipework, turbine shells or any heavy parts such as the rotor (Figure 3). The transition pieces for the 6C unit are backside impingement cooled by a perforated cooling shell Using aircraft technology The twelve-stage axial flow compressor has been designed by GE Energy with inputs from GE Oil & Gas and Aireraft Engines divisions (Figure 6). The uni- form stage pressure ratio of 1.28 is high- er than that of other GE Energy turbines but fall within GE's commercial aviation experience. A. scaled compressor test vehicle was assembled and tested at the GE Oil and Gas facility in Florence, Italy, in early 2003 to validate the design. The compressor rotor configuration includes forward stub shaft carrying three blade rows, 13 blade and wheel assembles, and an aft stub shaft. The forward stub shaft has axially ofiented broached slots for blade retention, Two sets of removable “1” airings are located between the rows and allow for removal and replacement of all he airfoils onsite without unstacking or re-balancing the rotor. The blades ate assembled by insertion into a loading slot and then by sliding them into position. As with the forward shaft this design allows for Feld removal of the blades. The rotor assembly is held together by Incone! 71 tiebolts.