WELCOME TO 1ST SESSION

BHEL GE GAS TURBINES COLLABORATION STATUS

GAS TURBINE FUNDAMENTALS
DESIGN FEATURES OF BHEL GAS TURBINES

COLLABORATION WITH GE, USA

Models covered

Fr-1 / Fr-3 / Fr-5 / Fr-6B / Fr-6FA /

Fr-9E / Fr-9EC / Fr-9FA / Fr-9H

Period

Started in 1986
Valid upto 2006

Coverage

Gas Turbine & Auxiliaries

Combined Cycle Engineering

Area

Compressive - Engineering
manufacture, E&C & Services
License for manufacture of rotor
and HGP components

HEAVY DUTY GAS TURBINE MODEL DESIGNATION

PG

APPLICATION
M- Mech.. Drive
PG- Pkgd. Gen..

SERIES
FRAME
1, 3, 5, 6, 7, 9

56

POWER

NO. OF
SHAFTS

(B)

SERIES

Approx.
1 or 2
output power
in Hundreds,
Thousands, or 10
Thousands of
Horsepower

004

GT MODELS AND RATING

Model
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)

MS1002
MS3142(J)
PG5371(PA)
PG6581(B)
PG6101(FA)
PG9171(E)
PG9231(EC)
PG9351(FA)
PG9551(H)

ISO Rating (kw)

5070
10450
26300
42100
70140
123400
169200
255600
380,000

ISO Efficiency (%)

24.5
25.6
28.5
32.0
34.2
33.8
34.9
36.5
-

Note: ISO output is : 15 deg C, 60% RH, Zero MSL, Gas fuel
and standard Inlet/Exh. Pr. drops

POWER(29.5 %)

FUEL
(100 %)

GAS
TURBINE

EXHAUST
HEAT
(67 %)

MISC.
(3.5 %)
OPEN CYCLE GAS TURBINE TYPICAL PERFORMANCE

GAS TURBINE REQUIREMENTS

Factors considered in selecting gas turbine
High efficiency
High specific output (output/kg of air flow)

Key Parameters of GT Affecting Above

Firing temperature
(Limited by metallurgy/cooling technology)
Pressure Ratio

MAJOR FACTORS AFFECTING

GAS TURBINE PERFORMANCE

Ambient Temperature
Altitude above Mean Sea Level (MSL)
Relative Humidity
Inlet Pressure Loss
Exhaust Pressure Loss
Steam / Water Injection for NOX Control
Type of Fuel

PRESSURE DROP EFFECTS (FOR FRAME -5)

4 INCHES H2O INLET DROP PRODUCES :
1.75% POWER OUTPUT LOSS
0.74 % HEAT RATE INCREASE
1.4 DEG.F EXHAUST TEMP. INCREASE
4 INCHES H2O EXHAUST DROP PRODUCES :
0.71 % POWER OUTPUT LOSS
0.71 % HEAT RATE INCREASE
1.4 DEG.F EXHAUST TEMP. INCREASE

EFFECT OF STEAM INJECTION

ON OUTPUT & HEAT RATE

INLET CHILLING PROCESS

Constructional Features of BHEL Gas Turbines

Heavy Duty Industrial Type

Skid concept to reduce site-work
Horizontally split casing for easy maintenance
Axial type compressor with Built-up Rotor
Wide Fuel flexibility : Gas & Liquid(light/Heavy)
Mixed Firing also
Cannular Combustion system with water/steam injection
/DLN combustors to meet stringent emission limits
Suitable for Mechanical/Power Generation/Single shaft
CCP applications

GT Rotor/Stator Arrangement
Compresor Rotor
Each wheel(stage) is bladed & statically balanced
Through bolts for wheels assembly
Total Rotor is dynamically balanced
Turbine Rotor
Each wheel(stage) with buckets & balanced
Through bolts for wheels assembly
Compressor & Turbine Rotor are built-up type
Compressor & Turbine Rotor joined by distance piece
to form one Rotor
Compressor Stator Vanes & Turbine Nozzles are fixed in
Comressor & Turbine Casing

COMBUSTION SYSTEM

Multiple Reverse flow can annular combustor

- easy for maintenance
- longer life due to lower dynamic forces
- allows full scale shop testing for non-standard fuels
- better temperature profile control
- high efficiency & lower emission
Each Combustor consisting of fuel nozzle, liner &
transition piece (for connecting to turbine)
Retractable electric spark plugs & UV flame detector
Cross fire tubes connecting combustors for flame
propagation

GT Cutaway Showing Casing Cross Section

NOx ABATEMENT

Nox is generated by fixation of Nitrogen in combustor

Nox generation depends on

- Flame Temperature
- Retention time in flame zone
- Fuel bound Nitrogen

Nox abatement methods

- By steam/water injection in flame zone
- By lean pre-mix mode (DLN combustor)
- By SCR (Selective Catalytic Reduction)

ACCESSORY BASE
Mainly consists of following systems
- Starting system
- Lube oil/Hydraulic oil system
- Gas/Liquid fuel system
In F-technology GTs these systems are independent &
off-base modules

STARTING SYSTEM

Electric Motor/Diesel Engine/Gas Expander

Torque converter
Electrical clutch
Hydraulic Ratchet/Rotor turning
Accessory Gear Box consisting of
- Over speed trip mechanism
- Lube oil pump
- Hydraulic oil pump
- Fuel oil pump
- Atomizing air compressor
- Water pump
Accessory Coupling (Gear, Diaphragm, Membrane))

LUBE OIL & HYDRAULIC OIL SYSTEM

Lube oil tank (as a part of base frame) with heater

MOP(shaft driven), AOP(AC) & EOP(DC)
Duplex (shell & tube) oil to water heat exchangers
Duplex filter (5 micron) with downstream SS piping
Main Hydraulic oil pump (shaft driven), AHP(AC)
with 0.5 micron filter
Cooling water supply
- by wet cooling tower
- air blast cooler

GAS FUEL SYSTEM

Stop/speed ratio valve, control valve (located in gas module)

On-base SS piping

Gas leakage detector & ventilation for Gas Module

LIQUID FUEL SYSTEM

Shaft driven booster pump (Gear/Screw type)
Suction stop & bypass control valve
5 micron high pressure filter
Flow divider (for equal fuel distribution)
Additionally air atomization by

- shaft driven air compressor (air extraction from last

stage of compressor, cooled in AAP & boosted)

- belt(diesel engine)/motor driven air booster compressor

during start-up

Gas Turbine

MS 5001PA
Basic Product Information
Construction
Compressor stages
Turbine stages
Number of combustors
Pressure ratio
:
Firing temperature
Load gear box rating
Load gear design

:
:
:
10.3
:
:
:

17
2
10
963C
31500KW
Single helical

MS 5001PA DESIGN FEATURES

17 stage axial compressor

Turbine & Accessory bases are skid mounted
Accessory base contains starting system, Lube oil console,
shaft driven accessory gear box driving Lube, Fuel,
hydraulic oil and atomizing air air compressor drives.
1st Nozzles air cooled
Diesel/Motor/Expander starting facility
Hot end drive.
Completely packaged and factory assembled, tested.

MS5001PA
Performance
ISO output (KW)
ISO heat rate (Btu/KW.HR),LCV
ISO efficiency(%)
Exhaust flow (Kgs/sec)
Exhaust temp. (C)
Speed (RPM)
105 Combined cycle
ISO output (KW)
Efficiency (%)
205 Combined cycle
ISO output (KW)
Efficiency (%)

Gas
26300
11990
28.46
124.16
487
5100

Distillate
25800
12070
28.27
124.44
488
5100

40

39
42

80.5

41.5
78.5

42.3

42.0

PLANT ARRANGEMENTS OF MS5001PA

Machine suitable for Indoor/outdoor installation

Skid mounted GT & Accessory packages
Suitable for Single Shaft and multi shaft combined cycle
Side or top exhaust
On-base / Off-base enclosure

FRAME-5PA GAS
TURBINE

GAS TURBINES FROM BHEL HYDERABAD

(as on Mar 2004)
TYPE

NO OF GAS TURBINES
ORDER RECEIVED

FR-1
FR-3
FR-5
FR-5/2
FR-6B
FR-9E
FR-6FA
TOTAL

4
16
45
2
52
11
6
138

COMMISSIONED

4
16
43
2
46
9
4
124

TOTAL BHEL GAS TURBINE LOGGED 6.8 MILLION FIRED HOURS

TOTAL MACHINES FIRING NAPHTHA 42 AND 1.6 MILLION HOURS FIRING EXPERIENCE
A : 006

12000 C

3
1104 0 C
9000 C

Q in
6000C

TEMPERATUR
E

3000 C

Gas Cycle
B

450 C
00 C

Q out

C
Steam Cycle

A
ENTROPY

EFFICIENCY

INCREASES BY 1 POINT FOR EVERY 600 C OF T3

COMBINED CYCLE COMBINES BEST OF :
BRAYTON CYCLE VIZ: HIGH TEMP HEAT ADDITION (11040 C)
RANKINE CYCLE VIZ: LOW TEMP HEAT REJECTION (45 0C)
EXPECTED COMBINED CYCLE EFFICIENCY = 48% TO 55%