04-12 Eng 9706
04-12 Eng 9706
04-12 Eng 9706
ABB developed the GTX100 gas turbine to meet growing market demand Compressor section
for power generation equipment that combines high reliability, low The compressor is a scaled-down version
emissions and high efficiency. Rated at 43 MW, the advanced, dual fuel of the LP compressor used in ABBs large
unit closes a gap in ABBs extensive gas turbine power range. NO x and GT24/26 gas turbines [2]. It has 15 stages
CO emissions with natural gas are below 15 ppm (15 % O 2) and with liquid and uses controlled diffusion airfoils for
fuel below 25 ppm (15 % O 2) over a 50100 % load range. maximum efficiency. The first three stages
feature variable geometry. To minimize
and has taken a lead in gas turbine With the GTX100, ABB has taken an- natural gas and below 25 ppm (15 % O2)
emissions control. In 1988 it introduced other step towards lower emissions. The on liquid fuel over a 50100 % load range
the first so-called EV burner to the combustor has 30 burners of the new without the need for water or steam injec-
market. To date, the total accumu- Advanced EV (AEV) design 3 . AEV tion. Dual-fuel DLE capability is a built-in
lated experience with this dry, low- burner technology was developed at the feature.
emission (DLE) technology amounts ABB Corporate Research Center in Extensive tests have been conducted
to more than 1.6 million operating hours, Dttwil, Switzerland, and, as applied in to verify the lower emission levels over the
including numerous GT10 installations the GTX100, will offer NOx and CO full load range of the machine, using liquid
[3]. emissions below 15 ppm (15 % O 2) on as well as gaseous fuels.
At 43 MW, the GTX100 closes a gap in the 2 AEV dry, low-emission burner used in 3
ABB gas turbine program. the GTX100
GT 1
GT 2
GT 7
GT 35
GT 10
GTX 100
GT 8 C
GT 11 N 2
GT 13 E 2
GT 24
GT 26
1 10 100 MW 1000
Turbine section Main gearbox design and the pressure gain in the upper
The three-stage turbine has been de- The gas turbine is connected to the and lower channels.
signed as a single module for ease of generator via a gearbox of the double The combustor and the burners have
maintenance and is bolted to the stub helical parallel type, which reduces the been tested extensively at the ABB works
shaft of the compressor. Its advanced 6,600 rev/min of the turbine shaft to a in Finspong, Sweden, at ABB in Switzer-
aerodynamic design features a fully 3D- generator speed of 1,500/1,800 rev/min. land, and at the CIAM test center in Mos-
analyzed flow path with cylindrical sec- The electric starter motor is connected to cow. Two combustor cylinders have been
tions over the first and second-stage the main gearbox via a self synchronizing built for design validation under hot con-
blades. The first and second-stage vanes and switching clutch and a separate start- ditions, at atmospheric as well as at full
and blades are cooled using the same ing gear. pressure.
technology as that used in the GT24/26. A full-scale model section of the com-
The first blade is made of single-crystal bustor has been built to verify design de-
material to ensure durability and long life. Design validation tails such as surface design, pressure
The turbine stator flanges are cooled by A comprehensive test program has drop and vortex breakdown. Special
compressor air to reduce clearances and been conducted to validate the design model tests have been conducted to ver-
improve efficiency. of the critical components of the ify the proper cooling at the combustor
The cold-end drive arrangement GTX100. outlet and the first vane 5 .
allows an optimized axial exhaust diffuser A scale model of the entire compressor The turbine cooling technology has
section to be fitted, resulting in better has been built and thoroughly rig-tested been verified in tests conducted at a
performance. Special attention given to at MTU in Germany. Tests in models of the newly-built hot test rig in Finspong, where
the design of the connection between the compressor inlet and plenum chamber cooling flows and heat transfer coef-
diffuser and the heat recovery steam have verified the flow characteristics and ficients can be measured 6 . Tests have
generator (HRSG) minimizes losses in the pressure drop 4 . Model tests have also been carried out to validate the
combined cycle and cogeneration appli- also been carried out on the diffuser sec- mechanical integrity of the first vane and
cations. tion behind the compressor to validate the blade film cooling designs.
Auxiliary systems
Lubrication
Since the two shaft bearings of tilting
pad design are lubricated with mineral
oil, a common lube oil system can be
used for the gas turbine, gearbox and
generator. In a combined cycle plant, the
lube oil system would be extended to also
include the steam turbine and its reduc-
tion gear.
Oil pressure is supplied by three 50 %
AC-driven pumps controlled by static fre-
quency converters.
Fuel systems
The GTX100 runs on a range of gas-
eous and liquid fuels, including natural Hot test rig used to verify the advanced turbine cooling technology 6
gas, LPG, naphtha and diesel oil. Two
fuel systems, for gaseous and liquid
fuels, are available; in dual-fuel opera- Control system The first node uses an Advant AC160
tion, automatic switch-over between The GTX100 control system is based on for closed-loop control of alarms and
the fuels is possible at full and part ABB Advant and has four controllers op- shutdowns, starting, synchronizing,
load. erating in four nodes: load and fuel-valve positioning.
22.5m
2 3 6 7 8
9
10
1 4
7m
5 13 12 11
15 14
14.5m
26.7m
4 5 6
1 3 9
7
8
2
10
11
12
The second node is an open loop for communicate with external systems via duction gear and starter motor. It rests
controlling sequencing and protection, standard buses. on a concrete foundation and may be
and is also based on the AC160. It fitted with spring mounts if required. The
takes care of the event handling, se- main and auxiliary skids are covered
quencing and interlocks, and produces Installation by a weather-proof enclosure extending
trend curves. The GTX100 installation meets todays from the gearbox to the gas turbine
The third node, a closed loop for market requirements by offering com- exhaust.
control of the generator, is based pactness, short erection and commis- The air intake and exhaust stack are
on the Advant AC110 and also sioning times, and ease of maintenance. supported by separate external beam
handles the voltage and generator pro- The gas turbine is skid-mounted, with structures. A two-stage disposable air
tection. the auxiliaries grouped in a self-con- filter is supplied as standard, but other
A fourth node, also in the generator tained module placed to one side options are also available. The standard
control panel, is responsible for syn- of the main skid. The footprint is only exhaust stack is 15 m in height; however,
chronizing, motor controls and open- 27 7 m. it can be built to other site requirements as
loop control of the lube oil. It is based The layout is basically the same for an option 7 .
on another AC160. all applications, whether simple or com- Electrical and control equipment may
Man-machine communication takes place bined cycle and whether indoors or out- either be installed in the customers con-
via an Advant 160 operator station, which doors. trol room or in a separate enclosure with
is a standard PC using Windows tech- The gas turbine skid is made of steel auxiliary power room, battery room and
nology. The Advant controllers can also beams and carries the gas turbine, re- control room 8 .
Generator Combined cycle units, each with its own HRSG, may
The standard model is a 4-pole generator In combined cycle applications the be arranged such that they feed a com-
of type GBA 1250AL, driven from the cold GTX100 can be arranged in a single-string mon steam turbine. One gas turbine
end of the gas turbine via the parallel configuration with the steam turbine would then operate separately, while
reduction gear. It is of simple and rugged driving a common generator. A dual- the other would operate in a single-
design and has a salient pole rotor with pressure HRSG feeds an ABB single-cyl- string arrangement with the steam
solid pole plates and a rotating brushless inder impulse steam turbine with an axial turbine. The total output would be
exciter. The GBA design is well proven, exhaust to the condenser. This well-prov- 124.5 MW.
having been used in numerous GT10 en configuration has been used in many
installations. GT10 combined cycle plants and offers a
The generator is installed outside of compact solution with a footprint of only Erection and commissioning
the main enclosure and is protected 60 20 m for the entire 62-MW power In order to shorten the on-site erection
from the weather by a roof. As an option, plant, including the boiler and all auxil- time, the GTX100 comes in modules
it may be fully enclosed. iaries 9 . which are assembled and tested in the
For higher power levels, two GTX100 workshop prior to shipment. Most of the
Side view (a) and layout (b) of the KAX100-1 combined cycle power plant 9
10 9 8 7 6
5
20 m
1 2 3 4
60 m
b
60
MW
55
50
45
1 40
P 35
2
30
20 10 0 10 20 30 C 40
0 100 %
T
P
Operation concept for part-load operation 10 GTX100 performance versus ambient temperature 11
1 0 angle P Load
2 Closing
piping and cabling work is also carried out valves at stages 5 and 10, which are open perature and closing the VGVs while
on the shop floor to minimize the time at the beginning of the starting procedure maintaining the exhaust temperature at
needed for this on site. and close during the start-up sequence. 600 C. When the VGVs are set to their
The biggest shipping module, weighing The starting sequence takes approxi- minimum positions, the load can be re-
a total of 76 tons, is made up of the gas mately 13 minutes, plus time for the venti- duced further by lowering the firing tem-
turbine, gearboxes and starter motor, lation, which varies from installation to in- perature 10 .
mounted on the main base frame. stallation. During operation, the load is The firing temperature and VGVs are
controlled by manipulating the variable also used to control load at high ambient
guide vanes (VGV) and the firing tempera- temperatures. For ambient temperatures
Starting and operation ture. Initially, the load is reduced by clos- above 35 C the VGVs are closed while
The GTX100 is started by means of an ing the VGVs until the exhaust tempera- the temperature rises and the firing tem-
electric starter motor connected to the ture reaches 600 C. Further load reduc- perature is adjusted to keep the exhaust
gearbox. The compressor has two bleed tion is achieved by reducing the firing tem- temperature below 600 C.
Performance
Table 1: If a gas turbine is to achieve high-level
GTX100 nominal performance under ISO conditions,
performance, due attention has to be
with open cycle
given to its intended operating cycle. In
Nominal performance, Natural gas Diesel oil no. 2 the case of the GTX100, market studies
ISO conditions
had revealed that combined and cogener-
Power 43,000 kW 41,400 kW ation cycles would become dominant in
Specific heat cons. 9,720 kJ/kWh 9,920 kJ/kWh the 3050 MW market segment, an as-
Thermal efficiency 37 % 36.3 %
sumption that has been borne out by re-
Exhaust mass flow 122 kg/s 123 kg/s
Exhaust temperature 546 C 548 C cent developments. Hence, the machine
has been optimized for such cycles, with
26
kg /s
24 D
1
22 t = 200C C
t = 250C
20
t = 300C B
t = 350C
18 A
t = 400C
V t = 450C
16
t = 500C O
GTX100 steam performance capability for an ambient 12 Inspection and maintenance intervals for 13
temperature of 15 C and pressure of 1.013 bar, the GTX100
with natural gas as fuel (LHV = 48,815 kJ/kg)
AD Maintenance program levels
P Steam pressure EOH Equivalent operating hours
V Steam production rate O Operation maintenance
1 Saturated steam
the pressure ratio set at 20 : 1. Table 1 Low life-cycle costs cost of 1 USD/MWh in this size range is
shows nominal performance figures for Two key elements of the life-cycle costs typically worth USD 4 million over 15
the GTX100. are the cost of fuel and maintenance. years.
The care taken in designing the Due consideration was given to these
GTX100 has contributed to its high level of already at the design stage of the
performance. In particular, the advanced GTX100, and as a result operators are Ease of maintenance
aerodynamic design, the use of abradable assured of low costs without any re- The GTX100 has a number of features
liners and low-expansion materials in the duction in the machines basic reliability that simplify maintenance and inspection.
compressor section, as well as features and availability. One side of the gas turbine has been kept
such as turbine stator clearance control The excellent performance figures in clean, avoiding unnecessary piping,
and the axial diffuser, contribute to the key applications keep fuel costs under cabling and connections, to allow for easy
high level of efficiency. control, an important requirement where inspection. Borescope ports are provided
In combined cycle operation based on fuel is purchased at world market prices. on the clean side for inspection of each
a dual-pressure, non-reheat steam cycle, A high level of efficiency is particularly compressor stage. A manhole with plexi-
the net output of the machine is 62 MW at critical when fuel is expensive, making glas window at the front of the inlet
54 % efficiency 11 . Excellent part-load combined cycle/cogeneration the pre- chamber allows easy inspection of the
performance is also achieved with 54 % ferred solutions. A drop in efficiency compressor inlet bellmouth.
efficiency maintained down to 70 % load of two percentage points will typically The compressor casing is split ver-
under ISO conditions. lead to an increase in life-cycle cost of tically in the longitudinal direction,
Cogeneration applications benefit from almost USD 5 million over a 15-year which allows half of it to be removed for
the high exhaust temperature, which period. easy access to the rotor and stator parts.
allows a high level of steam production, The basic robust simplicity of the The rotor center line is 1.6 m above
thereby meeting the demand require- GTX100 and an optimized maintenance the floor, making inspections very con-
ments of a wide range of process indus- schedule translate into very competitive venient.
tries and other consumers of heat, such maintenance costs. This is of signifi- The burner section has been designed
as district-heating networks 12 . cance, since a variation in maintenance so that each of the 30 AEV burners can
Outlook
The market for efficient and clean power
generation based on gas turbines in the
3050 MW range continues to grow at
the same time that customers are de-
manding equipment that can deliver high-
level performance without sacrificing re-
liability. The GTX100 gas turbine from
ABB has been developed to meet this de-
mand. It is designed to ensure very low
life-cycle costs and to be used for a wide
range of applications. These and other
features of the GTX100 are in line with
current as well as future customer
requirements.
References
[1] Mukherjee, D.: State-of-the-art gas
turbines a brief update. ABB Review
2/97, 414.
[2] Neuhoff, H.; Thorn, K.: GT24 and
GT26 gas turbines sequential combus-
tion the key to high efficiencies. ABB Re-
Removing the gas turbine from the installation 14 view 2/94, 47.
[3] Svensson, B.: Environmentally sound
combined cycle and cogeneration plants.
be removed individually without having for the gas turbine types concerned 13 . ABB Review 5/93, 1118.
to dismantle the machine. Easy inspection The time between major overhauls is
of the combustion chamber is also en- 40,000 equivalent hours.
sured. If required, the complete gas turbine
An overhead crane is installed inside can be replaced in 24 hours after it has
the gas turbine enclosure to facilitate cooled down to the necessary tem-
maintenance, and enough space is avail- perature. This involves disconnecting it
able to allow operating personnel to walk from the air intake and diffuser and
around the machine. The gas turbine can then removing it sideways on a rail
be removed from either side of the instal- assembly 14 .
lation. If required, the walls of the enclos- A comprehensive service portfolio is of-
ure can also be removed. fered by ABB that meets the individual
requirements of GTX100 customers. It
ranges from a simple support agreement
Maintenance program to full responsibility for preventive as well
A well-established maintenance program as corrective maintenance. Authors address
is available for ABBs industrial gas tur- ABB will also store emergency spares Bertil Nilsson
bines of types GT35 and GT10, and the and a spare gas turbine for emergency ABB Stal AB
same principles apply to the GTX100. In- back-up as part of its service agree- S-612 82 Finspong
spections and maintenance are carried ments. Sweden
out at intervals of 10,000 equivalent oper- Telefax: +46 122 186 84
ating hours and come in four levels, a phi- E-mail:
losophy which has ensured high reliability bertil.nilsson@sesta.mail.abb.com