Long Term Verification Results and Reliability Improvement of M501G Gas Turbine

2002 ◽  
Author(s):  
A. Maekawa ◽  
E. Akita ◽  
K. Akagi ◽  
K. Uemura ◽  
Y. Fukuizumi ◽  
...  
Keyword(s):  
Gas Turbine ◽  
Power Supply ◽  
Power Plants ◽  
New Technology ◽  
Initial Period ◽  
Operating Cost ◽  
Combined Cycle ◽  
Actual Condition ◽  
Steam Cooling

Large combined cycle power plants utilizing advanced gas turbine technology are in demand worldwide due to attractive $/kw installation and operating cost advantages. A combined cycle plant has been operating since 1997 to determine the long-term reliability and hot parts durability of 1,500 degree C class M501G gas turbine technology that utilizes steam cooling of the combustor hardware. The verification is being conducted at MHI’s in-house combined cycle verification power plant known as T-Point. The verification is conducted while dispatching power to a local utility to augment the summer peak demand period. The gas turbine has accumulated over 12,000 actual operating hours and 650 start/stop cycles since it is primarily applied under Daily Start and Stop (DSS) duty. To date the availability has been 98.6 per cent, where Availability is defined as the actual power supply hours over the demanded power supply hours. The DSS duty imposes severe thermal-mechanical conditions that also facilitate in the accelerated assessment of the long-term reliability and parts durability. During the initial period of verification nearly 1,800 items were checked with special instrumentation, and about 1,000 items continue to be monitored in order to better quantify the physics. This has been supplemented by annual detailed overhaul inspections of the hardware to compare the accuracy of the predictions versus actual condition. Such inspections also included the rotor after approx. 10,000 operating hours to verify the integrity of all the parts in the rotor train. The knowledge and experience from the long-term verification has enabled several improvements because of valuable quantified data. (e.g enhancements, steam cooling effectiveness, etc.) Such verification data is critical for being able to introduce steam-cooled technology in new land based advanced gas technologies such as “G” and “H” class. Those are also important steps in commercial introductions of the M501G and M701G steam cooled combustor technologies. This paper describes results from the verification of the new technology with respect to operation, and design enhancements focused at reliability and hot parts life durability improvement.

Steam Injected Gas Turbine (STIG) for Load Flexible CHP: Aspects of Dynamic Behaviour, Control and Water Recovery

2019 ◽  
Author(s):  
Thorsten Lutsch ◽  
Uwe Gampe ◽  
Guntram Buchheim
Keyword(s):  
Steam Turbine ◽  
Gas Turbine ◽  
Power Plants ◽  
Operating Cost ◽  
Combined Cycle ◽  
System Response ◽  
Water Recovery ◽  
Operating Range ◽  
Demand Fluctuations ◽  
Wide Operating

Abstract Industrial combined heat and power (CHP) plants are often faced with highly variable demand of heat and power. Demand fluctuations up to 50% of nominal load are not uncommonly. The cost and revenue situation in the energy market represents a challenge, also for cogeneration of heat and power (CHP). More frequent and rapid load changes and a wide operating range are required for economic operation of industrial power plants. Maintaining pressure in steam network is commonly done directly by a condensation steam turbine in a combined cycle or indirectly by load changes of the gas turbine in a gas turbine and heat recovery steam generator arrangement. Both result in a change of the electric output of the plant. However, operating cost of a steam turbine are higher than a single gas turbine. The steam injected gas turbine (STIG) cycle with water recovery is a beneficial alternative. It provides an equivalent degree of freedom of power and heat generation. High process efficiency is achieved over a wide operating range. Although STIG is a proven technology, it is not yet widespread. The emphasis of this paper is placed on modeling the system behavior, process control and experiences in water recovery. A dynamic simulation model, based on OpenModelica, has been developed. It provides relevant information on system response for fluctuating steam injection and helps to optimize instrumentation and control. Considerable experience has been gained on water recovery with respect to condensate quality, optimum water treatment architecture and water recovery rate, which is also presented.

Evaluation of Advanced Combined Cycle Power Plants

1998 ◽  
Vol 212 (1) ◽  
pp. 1-12 ◽  
Author(s):  
C Kail
Keyword(s):  
Combustion Chamber ◽  
Gas Turbine ◽  
Power Plants ◽  
Closed Loop ◽  
Cooling System ◽  
Turbine Blades ◽  
Combined Cycle ◽  
Steam Quality ◽  
Technical Problems ◽  
Steam Cooling

This report will analyse and evaluate the most recent and significant trends in combined cycle gas turbine (CCGT) power plant configurations. The various enhancements will be compared with the ‘simple’ gas turbine. The first trend, a gas turbine with reheat, cannot convert its better efficiency and higher output into a lower cost of electrical power. The additional investments required as well as increased maintenance costs will neutralize all the thermodynamic performance advantages. The second concept of cooling the turbine blades with steam puts very stringent requirements on the blade materials, the steam quality and the steam cooling system design. Closed-loop steam cooling of turbine blades offers cost advantages only if all its technical problems can be solved and the potential risks associated with the process can be eliminated through long demonstration programmes in the field. The third configuration, a gas turbine with a closed-loop combustion chamber cooling system, appears to be less problematic than the previous, steam-cooled turbine blades. In comparison with an open combustion chamber cooling system, this solution is more attractive due to better thermal performance and lower emissions. Either air or steam can be used as the cooling fluid.

Update on Mitsubishi G Series Gas Turbines With Over 78,000 Hours Fleet Operation

2003 ◽  
Author(s):  
V. Kallianpur ◽  
D. Stacy ◽  
Y. Fukuizumi ◽  
H. Arimura ◽  
S. Uchida
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Power Plants ◽  
Operating Time ◽  
Operating Experience ◽  
Combined Cycle ◽  
Air Cooling ◽  
Commercial Operation ◽  
Advanced Stages ◽  
Steam Cooling

Seven G gas turbines from Mitsubishi are in commercial operational at various combined cycle power plants since the first Mitsubishi G gas turbine was inroduced in 1997. The combined operating time on the fleet exceeds over 78,000 actual hours. Additional power plants using Mitsubishi G-series gas turbines are in advanced stages of commissioning in the U.S.A., and are expected to be in commercial operation in 2003. This paper describes operating experience of the Mitsubishi G-series gas turbines, which apply steam-cooling instead of air-cooling to cool the combustor liners. The paper discusses design enhancements that were made to the lead M501G gas turbine at Mitsubishi’s in-house combined cycle power plant facility. It also addresses the effectiveness of those enhancements from the standpoint of hot parts durability and reliability at other power plants that are in commercial operation using Mitsubishi G gas turbines.

Design Considerations for Syngas Turbine Power Plants

2015 ◽  
Author(s):  
Jaya Ganjikunta
Keyword(s):  
Power Plant ◽  
Gas Turbine ◽  
Gas Turbines ◽  
Power Plants ◽  
Low Cost ◽  
Operating Cost ◽  
Cost Savings ◽  
Combined Cycle ◽  
Technology Selection ◽  
Hazardous Area

Market demands such as generating power at lower cost, increasing reliability, providing fuel flexibility, increasing efficiency and reducing emissions have renewed the interest in Integrated Gasification Combined Cycle (IGCC) plants in the Indian refinery segment. This technology typically uses coal or petroleum coke (petcoke) gasification and gas turbine based combined cycle systems as it offers potential advantages in reducing emissions and producing low cost electricity. Gasification of coal typically produces syngas which is a mixture of Hydrogen (H) and Carbon Monoxide (CO). Present state of gas turbine technology facilitates burning of low calorific fuels such as syngas and gas turbine is the heart of power block in IGCC. Selecting a suitable gas turbine for syngas fired power plant application and optimization in integration can offer the purchaser savings in initial cost by avoiding oversizing as well as reduction in operating cost through better efficiency. This paper discusses the following aspects of syngas turbine IGCC power plant: • Considerations in design and engineering approach • Review of technologies in syngas fired gas turbines • Design differences of syngas turbines with respect to natural gas fired turbines • Gas turbine integration with gasifier, associated syngas system design and materials • Syngas safety, HAZOP and Hazardous area classification • Retrofitting of existing gas turbines suitable for syngas firing • Project execution and coordination at various phases of a project This paper is based on the experience gained in the recently executed syngas fired gas turbine based captive power plant and IGCC plant. This experience would be useful for gas turbine technology selection, integration of gas turbine in to IGCC, estimating engineering efforts, cost savings, cycle time reduction, retrofits and lowering future syngas based power plant project risks.

New Technology Trends for Improved IGCC System Performance

1995 ◽  
Author(s):  
A. K. Anand ◽  
C. S. Cook ◽  
J. C. Corman ◽  
A. R. Smith
Keyword(s):  
System Design ◽  
Gas Turbine ◽  
Gas Turbines ◽  
New Technology ◽  
Operating Cost ◽  
Careful Consideration ◽  
Combined Cycle ◽  
Air Separation ◽  
Separation Unit ◽  
Primary Output

The application of gas turbine technology to IGCC systems requires careful consideration of the degree and type of integration used during the system design phase. Although gas turbines provide the primary output and efficiency gains for IGCC systems, as compared with conventional coal fired power generation systems, they are commercially available only in specific size ranges. Therefore, it is up to the IGCC system designer to optimize the IGCC power plant within the required output, efficiency and site conditions by selecting the system configuration carefully, particularly for air separation unit (ASU) integration incorporated with oxygen blown gasification systems. An IGCC system, based on a generic, entrained flow, oxygen blown gasification system and a GE STAG 109FA combined cycle has been evaluated with varying degrees of ASU integration, two fuel equivalent heating values and two gas turbine firing temperatures to provide net plant output and efficiency results. The data presented illustrate the system flexibility afforded by variation of ASU integration and the potential performance gains available through the continued use of gas turbine advances. Emphasis is place on system design choices which favor either low initial investment cost or low operating cost for a given IGCC system output.

New Technology Trends for Improved IGCC System Performance

1996 ◽  
Vol 118 (4) ◽  
pp. 732-736 ◽  
Author(s):  
A. K. Anand ◽  
C. S. Cook ◽  
J. C. Corman ◽  
A. R. Smith
Keyword(s):  
System Design ◽  
Gas Turbine ◽  
Gas Turbines ◽  
New Technology ◽  
Operating Cost ◽  
Careful Consideration ◽  
Combined Cycle ◽  
Air Separation ◽  
Separation Unit ◽  
Primary Output

The application of gas turbine technology to IGCC systems requires careful consideration of the degree and type of integration used during the system design phase. Although gas turbines provide the primary output and efficiency gains for IGCC systems, as compared with conventional coal-fired power generation systems, they are commercially available only in specific size ranges. Therefore, it is up to the IGCC system designer to optimize the IGCC power plant within the required output, efficiency, and site conditions by selecting the system configuration carefully, particularly for air separation unit (ASU) integration incorporated with oxygen blown gasification systems. An IGCC system, based on a generic, entrained flow, oxygen blown gasification system and a GE STAG 109FA combined cycle has been evaluated with varying degrees of ASU integration, two fuel equivalent heating values and two gas turbine firing temperatures to provide net plant output and efficiency results. The data presented illustrate the system flexibility afforded by variation of ASU integration and the potential performance gains available through the continued use of gas turbine advances. Emphasis is placed on system design choices that favor either low initial investment cost or low operating cost for a given IGCC system output.

Development of Air Cooled Combustor for Mitsubishi G Class Gas Turbine

2010 ◽  
Author(s):  
Keizo Tsukagoshi ◽  
Hisato Arimura ◽  
Katsunori Tanaka ◽  
Koichi Nishida ◽  
Testu Konishi ◽  
...  
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Combined Cycle ◽  
Inlet Temperature ◽  
Air Cooling ◽  
Turbine Inlet Temperature ◽  
Steam Cooling ◽  
Cooling Technology ◽  
Verification Test

Mitsubishi Heavy Industries (MHI) pioneered the introduction of steam cooling technology for gas turbines with the introduction of the M501G in 1997. To date, 62 Mitsubishi G units have been sold making this series the largest steam cooled fleet in the market. The turbine inlet temperature (TIT) for this gas turbine is 1500 deg. C. The original M501G has been upgraded for air cooling applications. This upgraded version is called as M501GAC (G Air Cooled). Several Dry Low NOx (DLN) and cooling technologies from existing F and G series were applied to the upgraded M501GAC. The new GAC combustor was installed in the in-house verification Combined Cycle Power Plant, called T-Point, and verification tests of the combustor were conducted from November 2008. The air cooled M501GAC combustor demonstrated less than 15ppm NOx operation, stable combustor dynamics at all load levels, and high combustor ignition reliability making it suitable for daily start and stop operation at T-Point. Long term verification test is currently under way.

Development of Air Cooled Combustor for Mitsubishi G Class Gas Turbine

2011 ◽  
Author(s):  
Keizo Tsukagoshi ◽  
Shinji Akamatsu ◽  
Kenji Sato ◽  
Katsunori Tanaka ◽  
Hiroaki Kishida ◽  
...  
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Combined Cycle ◽  
Inlet Temperature ◽  
Air Cooling ◽  
Turbine Inlet Temperature ◽  
Steam Cooling ◽  
Cooling Technology ◽  
Verification Test

Mitsubishi Heavy Industries (MHI) pioneered the introduction of steam cooling technology for gas turbines with the introduction of the M501G in 1997. To date, 71 Mitsubishi G units have been sold making this series the largest steam cooled fleet in the market. The turbine inlet temperature (TIT) for this gas turbine is 1500 deg. C. The original M501G has been upgraded for air cooling applications. This upgraded version is called as M501GAC (G Air Cooled). The latest Dry Low NOx (DLN) and cooling technologies from existing F and G series were applied to the upgraded M501GAC. The new GAC combustor was installed in the in-house verification Combined Cycle Power Plant, called T-Point, and verification tests of the combustor were conducted from November 2008. The air cooled M501GAC combustor demonstrated less than 15ppm NOx operation, stable combustor dynamics at all load levels, and high combustor ignition reliability making it suitable for daily start and stop operation at T-Point. Also, oil firing capabilities was tested in May, 2010. Long term verification test is completed in fall 2010.

Thermoeconomic optimization of combined cycle gas turbine power plants using genetic algorithms

2003 ◽  
Vol 23 (17) ◽  
pp. 2169-2182 ◽  
Author(s):  
Manuel Valdés ◽  
Ma Dolores Durán ◽  
Antonio Rovira
Keyword(s):  
Genetic Algorithms ◽  
Gas Turbine ◽  
Power Plants ◽  
Combined Cycle

Natural Gas Decarbonization to Reduce CO2 Emission From Combined Cycles—Part II: Steam-Methane Reforming

2000 ◽  
Vol 124 (1) ◽  
pp. 89-95 ◽  
Author(s):  
G. Lozza ◽  
P. Chiesa
Keyword(s):  
Natural Gas ◽  
Gas Turbine ◽  
Partial Oxidation ◽  
Power Plants ◽  
Combined Cycle ◽  
Performance Estimation ◽  
Thermodynamic Efficiency ◽  
Methane Reforming ◽  
Operating Pressure ◽  
Carbon Conversion

This paper discusses novel schemes of combined cycle, where natural gas is chemically treated to remove carbon, rather than being directly used as fuel. Carbon conversion to CO2 is achieved before gas turbine combustion. The first part of the paper discussed plant configurations based on natural gas partial oxidation to produce carbon monoxide, converted to carbon dioxide by shift reaction and therefore separated from the fuel gas. The second part will address methane reforming as a starting reaction to achieve the same goal. Plant configuration and performance differs from the previous case because reforming is endothermic and requires high temperature heat and low operating pressure to obtain an elevated carbon conversion. The performance estimation shows that the reformer configuration has a lower efficiency and power output than the systems addressed in Part I. To improve the results, a reheat gas turbine can be used, with different characteristics from commercial machines. The thermodynamic efficiency of the systems of the two papers is compared by an exergetic analysis. The economic performance of natural gas fired power plants including CO2 sequestration is therefore addressed, finding a superiority of the partial oxidation system with chemical absorption. The additional cost of the kWh, due to the ability of CO2 capturing, can be estimated at about 13–14 mill$/kWh.

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