Power-GEN Middle East High efficiency gas turbine testing & validation Marcus H. Scholz Abu Dhabi, UAE 12-14, October 2014
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Agenda Gas turbine industry trends Systematic approach to validation - past & present 7F.05 gas turbine validation 9HA gas turbine unit #1 testing progress 9HA gas turbine unit #2 site progress Summary * Trademark of General Electric Company. 3
CC efficiency The industry trend efficiency & temperature Advancing efficiency to lower the cost of electricity Typical Efficiency vs. Temperature Relationship 62 60 58 56 54 52 2000 2300 2600 2900 F 1100 1260 1430 1600 C E-Class F-Class H-Class H-class >1430⁰C needed for >60% efficiency GE pioneered >1430 C a decade ago with H-class technology Six H-class units in operation >200,000 operating hours Last decade steam cooling used Today offering largest H-class gas turbine with air cooling (HA gas turbine) Gas turbine firing temperature Technology advances govern firing temperature to lower fuel costs 4
Experience matters 4,500 units 189 MM hours 2.6 MM starts Global installed base Fired hours Fired starts Gas turbine installed base ~1,000 GW Source: McCoy Power Reports, estimate based on reported orders. 156 120 GE Fleet All Others Reliability 97.8 97.4 +0.4 Availability 92.6 91.1 +1.5 Start Reliability 98.0 97.6 +0.4 Source: ORAP. All rights to underlying data reserved: SPS. Modified by GE. Rolling 12-month data Apr'13 - Mar'14. GE s leading experience feeds our technology advancements 5
GE s product portfolio Reliable, flexible, efficient GE GT-9HA GE GT-9F GE GT-9E GE GT-7HA GE GT-7F GE GT-7E GE GT-6F GE GT-6B.02.01.05.03.03.02.01.05.04.03.03.01.03 79 MW 51 MW 43 MW 90 MW 130 MW 227 MW 187 MW 299 MW 265 MW 330 MW 275 MW 397 MW 470 MW World s Largest 61%+ Net CC Efficiency 50Hz gas turbines 60Hz gas turbines Geared for 50Hz or 60Hz 6
A continuous progression of performance which builds upon experience GE industry firsts Invented F-class, 1986 (60Hz) Pioneered H-class, 2003 (50Hz) First single-digit DLN combustor First to 1,000 units (>150 MW) First in reliability & availability Today s H-class Air cooled Superior flexibility Merge of F and H-class experience Industry leading output and efficiency Succinct product growth of F-class and H-class heritage 7
Systematic approach to validation Rigorous validation approach.building on Aviation model Address high technical challenges early understand and mitigate Systematic stair-step building block Increasing commonality between platforms Science Component Sub-System System 2012 2003 2001 2004 A tiered process to build on reliability at final test 8
Combustion lab since 2001 DLN 2.6+ lab tested 210 combustion tests per year Validating: Emissions <25 ppm NO x (9HA) Fuel range (MWI) ±10% (9HA) Turndown 30% base load (9HA) Combustion dynamics Durability... and field validated 67 operating 9 F-class gas turbine units >1,300,000 fired hours Subsystem level validation with proven fuel flexibility 9
Advanced compressor test in 2011 7F.05 compressor 2011 9HA compressor 2013 Tested in June 2011 Fully mapped compressor 90% 110% speed range Two fully assembled rotors Fully instrumented Full load in 2014 Subsystem validation of capability with growth potential 10
GE s Aero Engine testing - a decade of validation Jet engine test cell Peebles, Ohio GE off grid test stand Greenville South Carolina Speed range 1 RPM to >3900 RPM Load range... 1 MW to 110% MW Transients Instrumentation > 3000 sensors Data acquisition terabites World-class validation inspired by aviation testing 11
Corrected flow Thorough validation prior to first fire in the field Unique 50 Hz and 60 Hz full load, variable frequency facility Example 7F.05 results Validation schedule 7F.05 2012 9HA 2014 7HA 2015 Unique facility validates full load and beyond Variable speed, load and pressure Validates extreme transient behavior Pressure ratio Compressor + GT validation 7F.03 fleet data (600+ units) System level validation on a lifecycle basis 12
7F.05 gas turbine acceptance and commercial operation validated in 2012 in GE s test stand facility Commercial acceptance enabled by GE s test facility Timeline Announced 2008 Test Stand validation 2012 COD 2014 Units on order 53 + tech selections 71 6 Units in service in Saudi Arabia Comparison basis: previous 7F versions Clear customer choice for reliable, cost effective power generation 13
Off-grid testing benefits No grid restrictions no speed limit Replicates all ambient extremes and operational transients Allows to derive full compressor operating map Can explore repeated surge or stall events Validates gas turbine prior to first fire Exploring growth potential Test bed capability exceeds any site operating envelope 14
Test stand validation for grid code compliance Off-nominal frequency operation Successfully tested steady state operation between 90-108% speed (54 64.8 Hz) Successfully performed 46 speed sweeps between 90-110% speed 7F.05 Loaded SS Off-speed Points Load control validation Successfully tested grid step response between -1% and +1% grid change Load changes >25% load /min. +1% Frequency Shift at 140MW 61.2 Hz 57.5 Hz Mass flow Typical grid frequency requirements Validation beyond global grid code requirements 15
HA gas turbine evolution A systematic progression of proven technology 9H 2003 9F.05 2005 7F.05 2012 4-stage VGV 4-stage turbine 9HA 2014 DLN 2.6+ 14-stage compressor Field-replaceable blades 3-stage VGV Advanced HGP Note: Year denotes first operation A decade of technology advances and lessons learned 16
9HA power turbine experience Performance and enhancements Double wall casing for tighter clearances (Hsystem) Advanced Gas Path (AGP) experience from 7F.04 and 7F.05 gas turbines 51 in operation 4-stage technology scaled from 9H gas turbine Aero engine sealing technology Hot gas path materials Single crystal technology Reduced oxidation and creep Improved low-cycle fatigue Air-cooled hardware for flexibility benefits F & H - turbine heritage Hot gas path material selection supports longest rotor life 17
First 9HA gas turbine assembled and shipped Jan. 2014 Turbine features: Superalloy rotor materials F-class materials Advanced cooling and sealing Compressor features: 14-stage, 3D aero configuration Pressure ratio 21:1 3 stages VSV Second generation air cooled H-class gas turbine 61% + CC efficiency 18
9HA gas turbine full load testing underway - October 2014 Results more relevant than 8,000 hour field operation Capabilities Variable frequency & load testing Gas fuel and liquid fuel options Load shedding and grid response characterization Pyrometry and real time IR cameras 9HA gas turbine #1 is fully dedicated to the test program 19
Start up tests ongoing > 3,000 data streams from the assembled test train 20
9HA instrumentation and number of sensors includes > 1000 thermal crystals Hot Gas Path >200 rotating >800 structures Combustion system >350 Stator vanes & blades >120 rotating >400 structures Complete test train contains > 500 rotating and > 3000 static sensors 21
9HA gas turbine 2 site construction EdF Bouchain: Site works ongoing Main control and power train behind ST condenser in place On schedule for commissioning end of 2015 22
HA experience and validation driving rapid order growth >25 Maintaining units technology 50 selected in 60 for momentum planned projects 23
Summary Component and subsystem tests build the foundation for the final systems validation 9HA gas turbine 1 installed & rotating firing imminent Large 600MW Generator passed running test successfully Industry leading testing & validation capability acknowledged through early orders pipeline for 7F.05 and HA technology. Commercial success is supported through insurance & financing institutions HA technology a new standard in technology validation 24