Journal of Power and Vol. 5, No.

2, 2011

Energy
Systems
Evolution and Future Trend of Large Frame
Gas Turbine for Power Generation*
Atsushi MAEKAWA**
**Mitsubishi Heavy Industries, LTD
35 Shinanomachi, Shinjuku, Tokyo, Japan
E-mail:atsushi_maekawa@mhi.co.jp

Abstract
Mitsubishi Heavy Industries, Ltd. (MHI) developed a 1100°C class D series gas
turbine in the 1980s and constructed the world’s first successful large-scale
combined cycle power plant. Since then, MHI has developed the F and G series gas
turbines with higher turbine inlet temperature and has delivered these units
worldwide accumulating successful commercial operations. These gas turbines are
constantly improved, adding to their successful operation. MHI is currently
participating in a Japanese National Project to promote the development of
component technology for the next generation 1700°C class gas turbine. The
thermal efficiency will be improved significantly with this new technology by
raising the turbine inlet temperature and the pressure ratio.
MHI recently developed a 1600°C class J series gas turbine utilizing some of the
technologies developed in the National Project. This paper discusses the history and
the evolution of MHI large frame gas turbine for power generation and the
activities currently in progress for an environmentally friendly technology in the
future.

Key words: Combined Cycle, 1700°C Class Gas Turbine, 1600°C Class GAS
Turbine, J Series Gas Turbine, G Series Gas Turbine

1. Background
The Kyoto Protocol came into effect in February 2005, targeting prevention of global
warming by developing environmentally friendly energy sources and energy conservation.
MHI contribute to pursue the balanced concept of 3E (Energy security, Environmental
protection, Economical growth). The simultaneous achievement of 3E requires (1) the
reduction of final energy use (energy conservation and improved efficiency on the user
side), (2) the improvement of energy conversion efficiency (reduction of primary energy
use), (3) the promotion of low-carbon energy use (nuclear power and renewable energy),
and (4) the recovery, storage, and use of generated CO2. Our company possesses a wide
variety of products and technologies that help curbing the negative effects of economic
growth that lead to increased energy consumption and CO2 emissions.
High conversion efficiency is aggressively targeted to reduce dependency on fossil
fuels and to reduce waste materials generated in energy conversion, while maximizing the
use of renewable energy such as nuclear, solar, wind, and geothermal. Steps have been taken
to further improve the already unsurpassed thermal power generation efficiency of gas
turbine combined cycle (GTCC) technology.
MHI has pursued increased efficiency from the introduction of the M701D gas turbine
*Received 18 Oct., 2010 (No. 10-231-6) (Turbine inlet Temperature (TIT) 1150°C) with the first Dry Low NOx (DLN) combustor.
[DOI: 10.1299/jpes.5.161] This was followed by the development of the F series gas turbine (TIT 1350°C) and the G
Copyright © 2011 by JSME

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Energy Systems

series gas turbine (TIT 1500°C) in 1997, with the first steam cooled combustor liner. The H
series, which expanded steam cooling technologies from the combustor liners to the row 1
and 2 blade & vanes, was tested in 1999 and 2001 with success.
Currently, MHI is engaged in a Japanese National Project that targets the development
of a 1700°C TIT gas turbine. Six component technologies are addressed in this project.
This paper describes:
(1) MHI G series gas turbine design features and upgrades experience. (1500°C TIT)
(2) The Japanese National Project 1700°C gas turbine component technology
development status.
(3) MHI J series gas turbine design features. (1600°C TIT)

2. History of Gas Turbine Development

Figure 1 shows MHI gas turbine development history. MHI developed the 1150°C class
large capacity gas turbine, M701D in 1981, and subsequently verified its high plant total
thermal efficiency, high reliability and low pollution at Tohoku Electric Power CO. Inc.,
Higashi Niigata Thermal Power Plant #3 Power Train. In 1985, MHI started the
development of the 1350°C class F series gas turbine (M501F/M701F). Its actual loading
shop test was conducted on the initial unit in 1989. This was followed by the development
of the 1500°C class G series gas turbine (M501G/M701G) in 1993. A trial operation of the
M501G gas turbine for 60Hz market started in February 1997 at the Takasago in-house
verification plant (T-Point) where it continued long term operation to validate its availability
and reliability characteristics. The M701G gas turbine for 50Hz market was started a trial
operation at Tohoku Electric Power Co. Inc., Higashi Niigata Thermal Power Plant #4
Power Train on October 15, 1998, and was put into commercial operation in July 1999.

1600 M501J M701J

Scale design High efficiency
Combined cycle
Up rating design
1500 M501G M701G
M501H
Turbine Inlet Temperature（℃）

Application of
Cogeneration
1400 M501F3 M701F3 G technology

M501F M701F

1300 MF-111 MF-221

M501DA M701DA
1200
MF-61
M501D M701D
1100
M251

M151 M501B M701B

1000
～
～

5 10 20 40 80 160 320
Power Output (MW)

Figure 1 Trend of increasing turbine inlet temperature

MHI is currently participating the actively in a Japanese National Project that targets 62
to 65% combined cycle efficiency through the development of a 1700°C class gas turbine.
Part of the component technology developed for the National Project is applicable to a new
1600°C class (J series) gas turbine. The target combined cycle efficiency of J is 60% or
higher and the 1on1 combined cycle output will reach 460MW for the 60Hz engine and
670MW for the 50Hz counterpart, as shown in Figure 2.

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Energy Systems

GTCC
Efficiency
Efficiency Power Output
GTCC Efficiency 700
1700Cclass
GTCC Configuration : 1 GT+1 ST
670
J Series 600 50Hz
60
G Series

Power Output (MW)

500 60Hz

GTCC Efficiency (LHV %)

GTCC 498
465 460 460
F Series 400
G/T 399
55 300 334
312 320
280 267
200 213
185
167
D Series 144
50 100 114

1200 1300 1400 1500 1600 1700 D F G J

Turbine Inlet Temperature (℃) Series Series Series Series

Figure 2 Mitsubishi gas turbine performance (Efficiency)

3. G Engine Evolution and Experience

3.1 G series Design Features
The basic structural design of the G series gas turbine followed the previous Mitsubishi
large industrial gas turbines, e.g. cold-end drive, two-bearing support, cannular type
combustor and 4 stage turbine. The key design features of the M501G gas turbine are
summarized in Figure 3.

Figure 3 M501G Design Features

The TIT can be increased to improve Combined Cycle (C/C) efficiency; however, this
also induces increased NOx emissions. In an air cooled combustor, cooling air flows into
the combustor inducing a reduction of combustion gas temperature. The flame temperature
reduction can be as high as 100°C for units that have 1500 or 1600°C turbine inlet
temperature.
By applying the closed loop steam cooling from the bottoming cycle, the turbine inlet
temperature is not diluted and therefore it remains high. NOx is directly related with the
flame temperature while the C/C performance is improved by TIT, therefore the steam

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Energy Systems

cooled combustor provides higher cycle efficiency with the same NOx emission. (Figure 4)

Air Cooled Comb (F technology) Steam Cooled Comb (G Technology)

Air Steam Flame Temp

Flame Temp Steam
(Supply) (Supply)
(Return)

Hot gas path

Hot gas path
1400℃
Turb Inlet Temp Turb Inlet Temp

Figure 4 Air Cooled Combustor vs. Steam Cooled Combustor

3.2 G series gas turbine verification and operating experience

The facility at T-point consists of
full scale power plant with a 1:1
configuration. Figure 5 shows a
Air Cooled
bird-view picture of T-point. While Condenser
the power plant serves as an HRSG
Steam
Turbine
important test verification plant, it
also dispatches electric power to a Control
local utility under contractual Gas Center
Turbine
expectations on high reliability and
availability. The supply of electricity Fuel Gas
Compressor
to the utility is primarily for
augmenting its peak demand during
summer. Figure 5 Bird view of T-Point

Operating Experience(Jun.28'97 ～July.31'10) Typical Operating Pattern

*
○ DSS operation mode

Standby Demanded
/inspection Start Power Supply Stop
579Days
Power Output

*
Continuous DSS operation
operation 1503 Days
342 Days

**
WSS operation
6:00 9:00 22:00 24:00
158 Days
○ Total Power Supply : 9.937 Bill kWH
○ Total Operating Hours : 38,367 hrs
○ No.of Starts : 2,249 times
○ Availability *** : 98.80% * DSS : Daily Start and Stop
○ Environment Parameters : Within Allowable Limit ** WSS : Weekly Start and Stop
(NOx,Noise etc.) *** Availability : (Actual Power Supply Hours)/(Demanded Power Supply Hours)

Figure 6 T-Point Operation Experience

Operation results at the T-point are shown in Figure 6. As of July 2010 the gas turbine
accumulated a total of 38,367 actual operating hours and 2,249 start-stop cycles.
MHI G series gas turbine operating fleet has grown to 39 units (66 units sold) and has
accumulated more than 1,098,000 actual operating hours and 11,300 starts (as of July,
2010).

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Energy Systems

4. Japanese National Project

The Kyoto Protocol come into
effect in February 2005 in an effort to Gas Turbine Steam Turbine
HRSG
prevent global warming. Japan is
committed to reduce 6% of the total
CO2 emission of 1990 in Japan from
2008 to 2012. Under this severe
target, it becomes fundamental to
improve the thermal efficiency of the Recirculation
gas turbine for GTCC. cooler
Recirculation Fan Recirculation Line
Based on Japan’s Basic Act on
Energy Policy enacted in 2002, an
energy plan was approved by Figure 7 Japanese National Project 1700°C
Japanese Cabinet in 2003. In Gas Turbine
response to this new plan, the Japanese Ministry of Economy, Trade and Industry promotes
the development of a high-efficiency gas turbine for power generation. This project pursues
an aggressive efficiency target through the development of a 1700°C gas turbine. The
combined cycle efficiency for this ambitious project targets 62% - 65%. As part of this gas
turbine project, core technologies are being developed and commercialized.
Key technologies for 1700°C gas turbine can be classified into the following six areas;
(1) Combustor with exhaust gas recirculation system
(2) Turbine cooling technology
(3) Super heat resistant material
(4) Thermal barrier coating
(5) High efficiency, high loading turbine
(6) High pressure, high efficiency compressor
The current status of the technology developments including analyses and experimental
results are reviewed.

Turbine
High Cooling Efficiency
Advanced TBC
Super Heat Resistant Material
High Efficiency, High Loading Turbine
Compressor
High Pressure,
High Efficiency Compressor

Combustor
Exhaust Gas Recirculation System

Figure 8 1700°C gas turbine design features

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Energy Systems

5. J series Gas Turbine development

5.1 J series Design Features
TIT increase is the key for achieving high combined cycle efficiency but involves the
difficult technical challenges that should be overcome through exhaustive R&D efforts and
verification test. The J series will operate at an intermediate TIT between the current
1500°C (G series GT) technology and the 1700°C (Japanese National Project) TIT involved
in the Japanese National Project.
The main features of the J series GT are:
- 1600 °C TIT
- 23:1 Pressure Ratio
- Application of the technology developed in Japanese National Technologies
such as;
1. Turbine cooling technology
2. Advanced thermal barrier coating
3. High Efficiency High Loading Turbine
The J series compressor is based on Mitsubishi’s H series compressor. It operates at a
higher pressure ratio than the G (23:1 vs. 21:1).

501J (320MW)

Steam
Steam Cooled
Cooled
Low
Low NOx
NOx DLN Combustor) (s)
DLNCombustor(s
16
16 cans
cans

Turbine
Turbine
improved
improved TBC TBC
High
High Pressure
Pressure Ratio
Ratio Row
Row 11- 44 cooled
cooled blades
blades
Compressor
Compressor Row
Row 1-3
1- 3 cooled
cooled vanes
vanes
15
15 stages
stages

Turbine inlet temperature 1600 °

ºC
Pressure ratio 23 C

Figure 9 J series gas turbine design features

5.2 Target Performance for GTCC

Incremental improvements in efficiency have been achieved with Mitsubishi G series
combined cycle. The J combined cycle is expected to achieve even higher efficiencies (well
above 60% LHV, low heating value). The power generation capacity of the J combined
cycle will be about 1.2 times that of the G.
The use of state-of-the-art technologies developed in the 1700°C TIT Japanese National
Project (Figure 10) in this 100 °C lower TIT flame allows for a smooth transition and
validation period.
Turbine Inlet Temperature (℃)

G type superalloy Cooling Technology

J type superalloy Cooling Technology

Improved Cooling technology ：+50℃

+50℃
Low thermal conductivity TBC：
TBC：+50℃
+50℃

Figure 10 Key technologies for higher temperature

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Energy Systems

5.3 Structural Design Features of J series Gas Turbine

The J series gas turbine maintains the basic structural design used in previous
Mitsubishi large industrial gas turbines as shown in Figure 12. The basic structure of J
series is similar to the exiting F and G series gas turbine.

Figure 11 J-series gas turbine rotor

An advanced clearance control system was applied on row1 and 2 blade rings for
operation with tighter clearances.

F G H J F series
series series series series

Cold End
✓ ✓ ✓ ✓
Generator Drive

G series
2-Bearing Rotor ✓ ✓ ✓ ✓

4-Stage Turbine ✓ ✓ ✓ ✓

Individual H series
✓ ✓ ✓ ✓
Combustors

Horizontal Split
✓ ✓ ✓ ✓
Casing
J series
Turbine Air Steam
✓ ✓ Cooled ✓
Cooled Blade

Cooled &
✓ ✓ ✓ ✓
Filtered Rotor Air

Figure 12 Mitsubishi large industrial gas turbines proven features

5.3.1 Advanced airfoil compressor

The J series compressor has the same air flow rate as the G series. The 23:1 pressure
ratio compressor is based on Mitsubishi’s H series compressor that has a pressure ratio of
25:1. A three dimensional design concept was applied to reduce the shock loss in the front
stage and the friction loss in the middle/rear stage in order to achieve higher compressor
efficiency. That concept was assessed by 3D-Reynoles-averaged Navier Stokes CFD code.
The concept was validated and the blade performance was measured in a three stage high
speed research compressor (HSRC).

5.3.2 Steam cooled combustor and evolving air cooled combustion technology
The latest combustor technology allows achieving the same NOx level in the original G
combustor without applying steam cooling. For NOx reduction, two key technologies

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Energy Systems

should be considered:
- Cooling air management to reduce the flame temperature while maintaining the
turbine inlet temperature
- Reduction of the peak flame temperature to decrease the NOx emissions
For J series gas turbine, the same combustion technology is used with steam cooling
combustor. The target NOx level is as low as G series gas turbine.
The steam flow rate can be adjusted to maintain the metal temperature of combustor
hardware.

5.3.3 Turbine
F-series G-series J-series
Metal temperature of ・Serpentine ・Serpentine + TBC ・Serpentine + Advanced TBC
・Advanced Film Cooling
turbine blade and vanes must
Film Cooling Film Cooling Advanced
remain below the allowable Film Cooling

temperature limit to maintain

the reliability at 1600 °C TIT
operation. The row 1 to 4
Serpentine
blades are cooled by coolant Cooling
Serpentine
Cooling
Serpentine
Cooling
（Turbulator）
discharged from compressor （Angled Turbulator） （Angled Turbulator）

exit with reduced temperature

by the outside cooler, while
the row 4 blade of G series gas
turbine is uncooled.
The advanced cooling Figure 13 J-series turbine cooling features
technologies, such as optimized shaped film cooling holes developed in the Japanese
National Project (Figure 13) are introduced. Through several heat transfer tests as shown in
Figure 14, such as measurements of film cooling effectiveness and heat transfer coefficients
in the rig tests, the cooling design for these blades and vanes are confirmed carefully. In
the final stage of the verification prior to the trial operation, the hot cascade test for row 1
vane were conducted in the test facility. <Component Test>
Metal temperature distribution and
pressure distribution of the profile and Component Test (Flat-plate)
endwall portion were measured with
Flat-plate test
embedded thermocouple and pressure Low Speed Research Turbine
transducers. The measured metal R1B platform

temperatures are confirmed to be lower

Middle Pressure cascade Test LSRT
than the allowable temperature.
For performance improvement, the
endwall contouring is applied in the row <G-Engine condition>
Middle pressure Test
3 and 4 vanes.
T-point (G-Engine)
The rotating blade material is made Rainbow Test
T-point
from MGA1400 alloy. Directionally <J-Engine condition> (G-Engine)

solidified casting is applied for row 1 to

High Temperature Cascade Test
3 blades and conventional casting for
row 4 blade. The stationary vane
material is made from MGA2400CC HTC Test (J-Engine) T-point (J-Engine)

alloy. The MGA 1400 and 2400 were

utilized in F/G series gas turbine. Figure 14 Verification of Turbine cooling
TBC (Thermal Barrier Coating) is
essential for the high performance gas turbine in order to reduce the cooling air flow while
maintaining durability. The focus was not limited to the development of advanced TBC
compositions, but also to the manufacturing, spray process and confirmation of TBC

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durability on the actual parts. After rig test, the advanced TBC was tested on the current
M501G1 row 1 vanes and blades at T-point. In addition, metal temperature was confirmed
to be much lower with the advanced TBC than the current TBC.

5.4 Verification Program for J-series gas turbine

The first M501J will be tested at “T-point”. The manufacturing of this unit is scheduled to
be completed in October 2010 and its installation at T-Point is scheduled in February 2011.
During the trial operation, more than 2,300 instrumentation probes will be installed in the gas
turbine, including about 100 sensors in rotating parts. After the trial operation, the operation
under the local utility grid will follow under a daily start and stop (DSS) mode. The subsequent
commercial M501J (60Hz) will be ready to delivery in 2011 and put into the commercial
operation in 2013.
The natural frequency of compressor and turbine blades were confirmed from 0 rpm to
3600 rpm in the high speed balancing facility. The rotor vibration level at the high speed
balancing machine was confirmed to be much lower than the allowable level. The M701J is the
50Hz of this new class. It was designed as a full scale design of M501J. The validation of the
M501J at T-point will provide very useful feedback for M701J.

Strategic R&D / Design 501J

Planning Design Implementation T-Point (60Hz)
Verification Test Commercial
2011 Operation
2013
(50Hz)
701J
Commercial
Operation
Ready for FOB 2016

Figure 15 Schedule for J-series Gas Turbine

Figure 16 M501J gas turbine rotor installed in the lower casing

6. Conclusion
Restriction in carbon dioxide emissions are generating controversy around the use of
hydrocarbon fuels. Compared with conventional coal plants, high efficiency natural gas
fired combined cycle plant can reduce carbon dioxide emission by 50%, therefore, the
benefit of high efficiency plant usage goes far beyond energy conservation. MHI upgraded
existing gas turbine frames targeting higher efficiency and durability. In the mean time, new
developments are pursued to produce leap changes in combined cycle efficiency.
MHI is actively participating in a Japanese National Project that targets 62 to 65%
combined cycle efficiency through the development of a 1700°C class gas turbine. Parts of

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Energy Systems

the component technologies developed for the National Project are applicable to a new
1600 °C class gas turbine called J.
With a combined cycle efficiency of over 60%, the J-series GTCC power generation
will achieve considerably lower
CO2 emissions and contribute to
worldwide efforts to reduce
global warming.
MHI will continue providing
products and services that enable
3E expansion and to promote
further innovation of our
technologies and business such as
1. Ultra-high temperature gas
turbine
2. IGCC (Coal Gasification)
3. GTCC + SOFC
(Solid Oxide Fuel Cell)
4. Advanced cycles
(Carbon Capture/ Nuclear gas
turbine)
MHI contributes to the realization
of the low carbon economy
through these technologies in the Figure 17 Future Plan of Fossil
future. Energy Power Generation

References
(1) Tsukagoshi, K., Muyama, A., Masada, J., Iwasaki, Y. and Ito, E., 2007, “Operating
Status of Up rating Gas Turbines and Future Trend of Gas Turbine Development,”
Mitsubishi Heavy Industries Technical Review, vol.44, No.4.
(2) Ai, T., Koeneke, C., Arimura, H. and Hyakutake, Y., 2009, “Development of an Air
Cooled G class Gas Turbine (The M501GAC),” ASME Turbo Expo, GT2009-60321.
(3) Takata, K., Tsukagoshi, K., Masada, J. and Ito, E., 2009, “Development of Advanced
Technologies for the Next Generation Gas Turbine,” The International Conference on
Power Engineering-09 (ICOPE-09).
(4) Koeneke, C., Arimura, H., Masada, J., Ai, T., Kishine, T. and Hara, H., “Development of
a New 1600 degreeC Turbine Inlet Temperature Large Flame Gas Turbine,” ACGT2009.
(5) Ito, E., Tsukagoshi, K. Muyama, A., Masada, J. and Okada, I., 2010, “Development of Key
Technologies for the Next Generation Gas Turbine,” ASME Turbo Expo, GT2010-23233.

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