Gas Turbine - Partload and Operational Tradeoffs

Michael A. Cocca
6B Users Conference | San Antonio, TX | June 19-22, 2017
© 2017, General Electric Company.
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presentation and the information herein are provided for information purposes only and are subject to change
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OR FITNESS FOR ANY PARTICULAR PURPOSE.

All relative statements are with respect to GE technology unless otherwise noted. 1

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4 Effectors for turbine operation + one

T-Fire/Fuel
flow
Air flow

Exhaust
Energy

Turbine/cycle
Pressure
efficiency
ratio

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Gas Turbine Effectors / Sensors
What are my effectors? What is FSR?
FPG2
FSR stands for Fuel Stroke Reference. FSR
ATID
(psig) is the key fuel control output, configured
Legend:
(F)
to be proportional to the fuel heat
SRV P consumption (BTU/sec). FSR can be
AFPAP
IGV – critical effectors thought of as though there it were the
(inHg)
S position of a single “virtual” gas control
TTXM – critical sensors valve for the turbine.
AFPCS
(F) (inH2O) CTIM
(Units) (F) Comb

~
Other Critical Control Parameters:
TFIRE- Firing temperature
C TNH T CRT – Combustion reference temperature
(%) TNHCOR – inlet temp-corrected speed
CPR – compressor pressure ratio
DWATT CPD
(MW) IGV (psig)
CTD TTXM
(F) (F)
What are fuel splits? IBH
A “split” is the proportion of fuel that is
What is IBH?
delivered to a particular combustion gas
passage. In any given DLN system
What is IGV? IBH stands for Inlet Bleed Heat. IBH refers to
configuration with N valves, there are N-1 IGV stands for Inlet Guide Vanes. recycling compressor outlet flow back to the
split effectors (since the sum of the fuel is IGV (csrgv signal name) refers to compressor inlet. IBH acts to increase air flow
prescribed by FSR, you lose one degree of the vanes at the compressor inlet through the compressor while decreasing air flow
freedom in splits). that affect air flow. Opening the through the gas turbine. The primary use is
IGV increases air flow through the Compressor surge and icing protection.
compressor and hence the gas
turbine.

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Every plant decision comes with tradeoffs
Increase Output

Increase Raise
Availability Efficiency

Improve Balance
Reliability Wear & Tear

Reduce Enhance Flexibility

Maintenance Costs

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Stretching or how to get more Flexible
Axial Fuel Staging (“Turndown Enhance”)
Greater operating flexibility with improved emissions

CTQ Performance*
Fuel Flex 32% H2 content
Emissions 0.7 ppm NOx or 85% CO reduction
Turndown Down to 30% of Baseload
* Estimated values based on NG operation at ISO conditions. Illustrative purposes only.

Potential additional benefits:

➢ Up to 2% fuel burn reduction at part load
➢ ~0.4% simple cycle efficiency improvement
➢ Peak fire up to +100F while remaining NOx
compliant (alternative to turndown capability)
➢ Wider ambient temperature emissions compliance

✓ Extends the combustion system by 8”

✓ Applicable to both DLN1 and DLN1+
✓ Available to quote 6

© 2017 General Electric Company. Confidential information. All rights reserved.

Axial Fuel Staging (“Turndown Enhance”)
Hardware AFS CM&U Difference between DLN1+ LN and ULN
Transfer Style Transferless Style
Secondary Fuel Nozzle May use existing parts DLN1+ LN-Flanged
Identical
DLN1+ULN-Flangless
Endcover Assembly May use existing parts Identical
Combustion Casing May modify existing casing Identical
2 rows of mixing holes on DLN1 vs. 3 on ULN, and thicker
Liner Modify or buy new
liner stops on ULN
Flow Sleeve Modify or buy new Identical
AFS Injectors New part Identical
AFS Thimbles New part Identical
Transition Piece Use existing design Different dilution holes
Cross-Fire Tubes New part Identical

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 Features and benefits
DLN turndown enhance
DLN Turndown Enhance injector
• Reduced NOx (~25%) – concurrent NOx and CO emissions reductions also
achievable with compliant operations
• Extended CO compliant turndown2 – from 60% to 35% of peak load1 DLN Turndown Enhance headset

• Emission compliant peak fire2 – additional output – Up to +100°F Tfire TP Modified with DLN Turndown Enhance headset

increase with same current NOx levels1

• Improved ambient operating range 1
• Combustor pressure drop reduction – up to .4% improvement in SC Wrapper Penetration Assembly

efficiency1
• Part-load simple cycle efficiency – up to 2% fuel burn reduction (higher air and
pressure ratio) 1
• Commonality/flexibility/tunability – reduced need for dilution retunes1 TP Modification to add four new chamfered dilution holes

Operational flexibility, increased output and efficiency – retrofittable

1Compared to current 9E DLN combustion system without DLN Turndown Enhance
2Emision compliant peak fire cannot be combined with Extended compliant turndown 8
© 2017 General Electric Company. Confidential information. All rights reserved.
Using power of Digital for Flexibility
Upgraded fundamental control technology

Baseline DLN1 control Iso-Therm

-

MINIMUM
• Single temperature control curve - multiple Control Curve
operational boundaries implicit Tx_request

Tx
• No corrections CPR

CPR

CPC
Corrected Parameter Control
Iso-Therm
CPR
CPR
SH
• Four separate calculations for primary SH
DPin
DPin
Tfire
boundaries: Performance, Tfire, CO, NOx Performance DPex

MINIMUM
DPex Boundary
CTD

MAXIMUM
• Corrections for ambient temperature,
CTD

humidity, inlet/exhaust pressure drop CPR

SH CPR
• Additional sensors; humidity & ambient TCs DPin
CO
SH
CPC
DPex DPin
Boundary NOx
CTD DPex Boundary
CTD
CPR – Compressor Pressure Ratio
CTD – Compressor Discharge Temperature
CMHUM – Specific Humidity
DPin/ex – Inlet and Exhaust Pressure Drop
CDM input (optional)
© 2017 General Electric Company. Confidential information. All rights reserved.
Enhance DLN Performance

AUTOTUNE LT & DX
• Correct parameter control – tighter
control (Tfire, NOx, CO, dynamics)
• Automated fuel split adjustments
• CEMS feedback optional (DX)

AUTO RECOVER from

primary re-ignition
• Automatic vs. manual discovery
• Load reduction of ~5% vs. ~50%
• Automatic return to premix
~15 seconds vs. 10-30 minutes

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Reduce unnecessary trips
OpFlex* Trip Avoidance

TRIP AVOIDANCE
• Improved logic to avoid trips
• Intelligent signal selection and use
• System level data validation
• Alternative protective actions

Examples
− Exhaust spread and over-temperature logic
− Secondary flame detector sensing logic
− Transfer purge protection
− Valve position faults
− Null bias compensation for gas control valve
− Enhanced vibration sensing and logic

12
*Trademark of General Electric Company.
© 2017 General Electric Company. Confidential information. All rights reserved.
Identify faults before startup
OpFlex* Start Assurance

STARTING RELIABILITY
• Start permissive rationalization
• Pre-start system checks
• Start sequence display showing start
process status
• Check system at any time upon command

START PERMISSIVE SWEEPS PROVIDING HIGHER RELIABILITY

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© 2017 General Electric Company. Confidential information. All rights reserved.
Predix*: Connecting Data and People
Throughout the Organization
Accessibility | Scalability | Ecosystem | Custom Apps

Maintenance Manger Plant Manager Asset Manager Trader CEO

*Trademark of General Electric Company

© 2017 General Electric Company. Confidential information. All rights reserved.
 Efficiency optimizer: How it works
Edge UI Edge supervisory control Power plant equipment Plant Assets
Configured to take user Gas turbines
inputs on current User interface Power plant
HRSG’s
ambient and target plant Commands and benefits Heat rate
Steam turbine
output conditions; ability
to run in manual or auto- Condenser
Optimizer Unit controls
optimize mode Solver engine Cooling tower
Cycle levers

Digital twin Cycle levers

Physics models and
Setpoints GT turbine
temperature
tracking filters to match Digital twin GT inlet guide vanes
the physical plant; Plant thermal models
GT inlet bleed heat
feeds the optimizer
Target Current GT load balancing
with plant cycle HR HR
ST turbine
parameters to solve for
temperature
best HR setpoints
ST pressure

Optimizer
Periodically solves for minimum plant heat rate (HR) by generating optimized supervisory setpoints
(“cycle levers”) for the key production assets in the power plant. The result is reduced fuel consumption from
part load to baseload relative to the plant's baseline operating conditions 15

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 Digital delivers additional efficiency between intervals

Upgrades provide benefits

post outage
Current HR Digital adds ongoing value
between intervals
Constantly tuning for best
operating setpoints given
Heat rate decrease ambient conditions, fuel
due to AGP composition at base load and
part load
Heat rate

New AGP
.5%
Digital 1 time HR improvement
optimized Post outage from Major
inspection and AGP

+ 0.5 % with Digital

Time

16

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Questions?