GE Energy LMS100 Gas Turbine System A flexible growth platform to meet changing energy needs.
The LMS100 game changing technology from frame and aero gas turbines LMS100 CFM TECH56 CAPPs Combustor LM6000 F/H Technology Compressor Heat Exchanger Packaging GE90 High Pressure Ratio (42:1) Advanced Controls MK VIe, Smart Sensors Synthetic Logic LM6000 Sprint Intercooling 100MW 44-50% efficiency High part power efficiency Cyclic capability 10 minute starts Load following ability 2 /
Combining the best of both worlds Intercooler System CF6-80C2 High Pressure Compressor (HPC) CF6-80E High Pressure Turbine (HPT) Power Turbine Shaft Exhaust Diffuser MS6001FA Low Pressure Compressor (LPC) Single Annular Combustor (SAC) (DLE not shown) Power Turbine (PT) Intermediate Pressure Turbine (IPT) 3 /
Modular gen-sets Simple Cycle Exhaust GT Driver Package Dual Rated Generator Variable Bleed Valve (VBV) System Air to Water Intercooler MS6001FA Inlet System Cooling Tower 4 /
Typical plant arrangement Cooling Tower 50 m Power Control Module Gas Fuel Heater 50 m 5 /
Flexible power with high efficiency 50Hz Configurations / Applications* SAC-Water DLE SAC-STIG DLE-CC*** Gen Terminal Plant, MW 102.8 99 110.8 116 Gen Terminal Heat Rate, KJ/KWH LHV 8,173 7,921 7,263 6,700 NOX Emissions, mg/nm 3 ** 50 50 50 50 Hot day power 10 minute starts Fast load response WITH Part power efficiency Lower mass emissions Modular maintenance Assumptions Altitude sea level * 50 Hz, Rated Power, Average Engine HR, Methane Fuel, Rounded Values, Temperature / Rel. Humidity 15 o C/60% Excludes Intercooler Fan Loss No Inlet / Exhaust Losses ** 15% O 2, Without SCR, Natural gas *** Inlet / Exhaust losses = 101.6mm / 381mm H 2 O 6 /
Simple Cycle Efficiency Game changing power and efficiency in cycling duty segment 50% STIG 48% 46% SAC w/steam 44% DLE SAC w/water 42% 40% 10% Improvement over best available 38% 7FA M501F 36% 34% 32% V64.3A 6FA 7EA GT11NM M501 GT11N2 W501D5A 9E M701 V94.2 GT13E2 30% 60,000 80,000 100,000 120,000 140,000 160,000 180,000 200,000 GT Output (kw) 7 /
Great hot day performance 8 /
Dry motor / purge Ignition Accel to SI XN25 (RPM) Accel to max Water on at ~ 30MW Sync idle Decel to min idle Min idle Cooldown Shut down 10 Minute starts to full power XN25 Aero gas turbines are designed to cycle 10000 <8 sec to max power climb Cruise 8000 Thrust Reverse Typical Aircraft Engine Transient 6000 4000 High strength alloys, lighter sections Designed for cyclic life No start cycle penalty for maintenance intervals 120 sec accel & decels 2000 Typical Aeroderivative Industrial Engine Transient 47 / 5/3/2005 0 0 200 400 600 800 1000 1200 1400 1600 1800 2000 Time (sec) 9 /
50MW in less than a minute 10 /
LM modular maintenance philosophy Replaceable Supercore (24 Hr change out) Maintenance Intervals: Hot Section - 25,000 Hrs Overhaul - 50,000 Hrs (All maintenance interval same as LM6000) Rotable Modules: - Combustor - HPT - IPT - PT Total down time < 4 days with rotables 11 /
Rotable modules for onsite overhauls HPC Combustor HPT IPT TMF Typical HPT Rotable Workscope Tear down rotor & stator Repair / replace S1 blades, S1N, S2 blades & S2N Balance / repair stator Replace stator shrouds High speed grind HPT rotor to match fit with stator 12 /
Typical Aero Service Intervals Interval Scheduled Maintenance Action Outage Duration 4,000 hours (every 4K h) Borescope Inspection (includes cool-down time) 12 hours 25,000 hours Hot Section Interval* 50,000 hours Depot Maintenance (b) 1) On-Site Hot Section Replacement (Combustor, HPT, IPT) 1) Major Hot Section Overhaul (Combustor, HPT, IPT) 2) Inspect Booster, Intercooler, Scroll Frames, HPC, Aft Shaft & Bearings (c) 3) Power Turbine Overhaul 75,000 hours Hot Section Interval (b) 100,000 hours Depot Maintenance (b) (a) (b) (c) 1) On-Site Hot Section Replacement (Combustor, HPT, IPT) 1) Major Hot Section Overhaul (Combustor, HPT, IPT) 2) Inspect Intercooler, Scroll Frames, HPC, Aft Shaft & Bearings (c) 3) Power Turbine Overhaul 4) Booster & Shaft Inspection/Maintenance Rotable module installed during maintenance period Lease/spare supercore and Power Turbine modules are installed during maintenance period. For depot maintenance, outage duration is 60 days if no spare/lease module(s) are used. Roller and ball bearings are replaced at 50,000 hours; hydrodynamic bearings are inspected. 4 days (a) 4 days (a) 4 days (a) 4 days (a) 13 /
I/C Temperature, (F) Deg C Exhaust Temperature, (F) Deg C Potential for >90% CHP efficiency utilizing intercooler and exhaust energy 400 300 200 ~25-30 MWT ~70-80 MWT Degrees C -10 0 10 20 30 40 50 Hz 60 Hz 0 20 40 60 80 100 120 Inlet Temperature (F) 200 150 100 Intercooler HRSG 820 800 780 760 740 720 700 Degrees C -10 0 10 20 30 40 50 Hz 60 Hz 0 20 40 60 80 100 120 Inlet Temperature (F) 420 400 380 14 /
Value in all applications Application Simple Cycle peaking Simple Cycle Mid-range dispatch Combined Cycle CHP steam to process CHP District Heating Coal Plant Feed Water Heating Capability / Benefits Cyclic ability with low maintenance and installed cost High efficiency/low installed cost Small steam plant @ 54% High power/steam ratio Flexibility power or process steam >90% efficiency max energy use 57-60% gas to electric conversion 15 /
LMS100 makes feed water heating applications extremely attractive High gas energy to electricity conversion > 47-54% for sub-critical repowering applications > 57-60% for new super-critical applications Project costs lower than combined cycle GT Integrated plant part power flexibility Lower plant emissions 16 /
Low pressure compressor MS6001FA 17 Stage Compressor >8 Million hours of operation LMS100 LPC - 1 st 6 Stages of 6FA Compressor - Same operating speed - Same flow, pressure and temperature - Variable speed operation LMS100 LPC 17 /
Core high pressure rotor CF6-80C2/E Introduced - 1985 Operating hours >100 million LMS100 Core - HPC derived from CF6-80C2 - HPT derived from CF6-80E - Lower shaft speed - Lower T3 - Increased firing temperature LM6000 Introduced - 1991 Operating hours > 9,000,000 18 /
Standard Annular Combustor (SAC) LM6000 LMS100 Design LMS100 Design basis LM6000 Same CRF Volume & Diffuser Areas Redesigned for Operability & Performance: - Fuel Nozzle - Swirler - Liners Areas Redesigned for Reliability Improvements: - Fuel Nozzle - Swirler / Ferrule - Splashplate - Domeplate Cooling pattern - Venturi 19 /
High Pressure Turbine (HPT) 2-stage turbine Same hot flowpath and materials as LM6000 Based on CF6-80C2/E boltless rotor design with over 500,000 EOH Increased flow capability Operating Conditions (vs LM6000) - Pressure ratio 30% lower...lower stress - Cooling temperatures 250F colder - Cooling flow higher Same metal temperature - T41 8% higher - Rotor speed 7% lower...lower stress 20 /
Intermediate Pressure Turbine (IPT) New design 2-stage turbine Same materials as HPT Based on successful HPT designs - Same design practices IPT frame based on successful GE90 design Drives the LPC through a mid-shaft and coupling: - Mid-shaft material and design same as LM6000 - Modified LM2500+ US Navy main drive coupling - Both operating at higher speeds and lower torque 21 /
Power Turbine PT Sub-base Assembly (ALF) PT Shaft (ALF) Aft (Hot End Drive) New design 5-stage turbine Same materials as LM6000 Based on successful LPT designs for all GEAE LPT s Same pressure ratio, speed and inlet temp as LM6000 PT Case (Now fully Assembled)) 22 /
Intercooler heat exchanger experience TEI Examples of manufacturing capability P/N Girth Length 9941 110' - 6" 44' - 8" 9942 105' - 9" 43' - 2" 0014 107' - 8" 44' - 4" 0156 117' - 0" 47' - 4" 0212 111' - 8" 48' - 2" 0238 110' - 8" 44' - 0" Design and Test: - GEAE and GEPS Chief Engineers reviews - GEPS H machine experience applied (heat exchangers) - Component test at GE-Global Research Center Operating Experience: - Widely used for 40+ years in air industry - Equivalent flows - Higher pressures - Higher temperatures - Air and multiple gases - Supplier validated heat exchanger code 23 /
Redundancy a key reliability feature All reliability key sensors typically include 3 sensors or 2 dual element sensors Each signal routed to independent I/O block, eliminating single point failure modes Each I/O block communicates to multiple control processors through 2 independent networks Each I/O pack is power by two independent power supplies Power supply for the control includes a UPS system for backup in loss of AC power Mineral lube oil system includes redundant AC pumps and a backup DC pump Intercooler system includes dual 100% circulation pumps. Turbine hydraulic systems include redundant AC pumps and a backup DC pump Turbine enclosure ventilation includes redundant fans Generator ventilation includes redundant fans Power turbine load cage cooling includes a redundant blower. 24 /
GE committed to providing the best product at the lowest risk Robust NPI process Operating conditions within current experience levels Design based on existing gas turbine components and modules Full scale validation testing Fleet leader program Reliability roadmap 25 /
Comprehensive full scale validation tests Combustor rig Instrumented core engine Production core engine Instrumented power plant (FETT) Production gas turbine generator set 26 /
GE s altitude test facility ideal for matching LMS100 operating conditions Provided required flow rate, at depressed inlet temperatures and elevated inlet pressures to simulate the LMS100 intercooler discharge conditions. 460 lbs/sec airflow 35-38 psia inlet pressure ~110 F inlet temperature 27 /
Core engine test vehicle heavily instrumented Dual fuel combustion system liquid (Jet A / Diesel) or natural gas with water injection capability Configured with both forward and aft instrumentation slip rings. Slave front frame and aft frame from flight engines Core Engine Cross-Section Over 1500 pieces of instrumentation system or component pressures, temperatures, and mechanical strains (stresses). 28 /
Successful core engine test Great results 66+ hours / 74 starts 2 engine cell installations and test June & November 2004 Collected significant data: 500 transient data recordings 800 steady-state recordings Achieved 100% start reliability Rotor thrust balance verified Cleared all rotating hardware for aeromechanics Demonstrated core engine mechanical integrity 29 /
LMS100 full load test stand Test facility capacity 120MW load banks VBV silencer stack Variable bleed valves (VBV) Evap cooling towers Modified 6FA inlet system First-Engine-to-Test (FETT) instrumentation data trailer Auxiliary skid Intercooler/ Heat exchanger Intercooler water pump skid 30 /
Full load test objective validate simple cycle power plant design Full load test of the gas turbine generator set Fully operational intercooler system Complete package validation Mark VI control system validation Auxiliary skid ring-out Full sensor suite across GT and package Over 2500 sensors installed Full range of operation covered 31 /
Significant accomplishments Total test time: 121 hrs Gas 110 hrs Liq 11 hrs Total # starts: 69 Operated at max power conditions 110MW s meeting requirements Demonstrated ability to meet heat rate requirements Demonstrated 10 minute start ability Demonstrated load following ability Demonstrate ability to meet emissions requirements Conducted aeromechanic evaluations Evaluated rotor system vibration Conducted operability studies Conducted transient studies Validated all subsystems; MLO, start, fuel, water injection, gas and liquid fuel Demonstrated intercooler loop Variable Bleed Valve (VBV) system Demonstrated start capability on gas and liquid fuel Demonstrated gas fuel operation with water injection 32 /
10-minute starts validated HP rotor speed Power IP rotor speed PT rotor speed 10:48 min to 100 MW Load ba nk adjustments caused delays Not typical for grid operation Adjusted time < 10 minutes 33 /
Emissions at 15%O2 (ppm) Fuel flow (pph) LMS100 PA Startup / Shutdown Emissions Profile 3000 Ignition Accel to power Warm Up Cool down 40000 2500 2000 CO15_M 10XNOx_15_M WF36corr 35000 30000 25000 1500 20000 1000 15000 10000 500 5000 0 0 0 200 400 600 800 1000 1200 1400 1600 1800 2000 Time (sec) Sync NOx Water on Fuel off NOx water off * NOx values shown are the actual values multiplied by 10, for purposes of plotting. 34 /
Reliability thru commonality while maintaining flexibility Product Type Model Application Intercooler/ Cooling Tower (Fuel Sys) 50Hz 60Hz Dry Wet LMS100 PA Gas Dual Steam STIG LMS100 PB DLE Common 50/60 Hz generator...+ fleet reliability Common GT and Package both intercooler system..+ fleet reliability No gearbox required for 50 or 60 Hz applications. + performance and cost Intercooler options..+ site conditions flexibility STIG Steam Injection for power augmentation 35 /