PowerGen Europe 2013

Vienna Jun 4-6, 2013

Operational Experience of Mitsubishi M501J GT
Junichiro MASADA1, Satoshi HADA1 , Susumu WAKAZONO1
Yasushi FUKUIZUMI2, Takashi KISHINE2, Carlos KOENEKE2
Mitsubishi Heavy Industries, Ltd. JAPAN
1
Gas Turbine Development Takasago Machinery Works
2
Mitsubishi Power Systems Americas, Inc

Abstract

The M501J is Mitsubishi Heavy Industries (MHI) 60Hz largest and most advanced gas
turbine. This new frame, designed and manufactured using advanced technology developed
for a Japanese Government funded project called “The Japanese National Project” has been
commercially operated at MHI Validation plant T-Point in Takasago since July, 2011.

The first M501J was installed in MHI Validation plant T-Point in Takasago, Japan in
November 2010 and started verification operation in Feb, 2011. This unit has successfully
exceeded 10,000 Actual Operating Hours (AOH) as of Feb 2013.

Sixteen M501J have been sold in Asia. The first of six single-shaft blocks at Himeji II Power
Station project in Japan is in advanced stage of commissioning. The second unit is on base.
Four of the six blocks are scheduled to be commercial by the end of 2014 and the remaining
two in 2015.

As part of the future J development, and following the successful approach applied in 2009 to
the steam cooled G, an air cooled version of the J will be tested in 2014 to make it available
for shipment in 2015.

This paper describes the main features of this 1,600 °C (2,912°F) “Turbine Inlet Temperature”
(TIT) turbine and presents operational results of the T-Point as well as Kansai Electric first
Unit operation.

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Introduction

Historically high energy prices in Japan have been a powerful driver to pursue high efficiency
gas turbines. Among others, increasing TIT is an effective way to improve efficiency. Figure 1
below shows the evolution of MHI large frame gas turbines starting with the D Class at TITs
in the range of 1,250ºC to the current highest TIT in the market at 1,600ºC.

Figure 1. MHI C/C Efficiency Historical Trend

This energy evolution has involved engineering challenges that have been successfully
addressed through R&D and thorough validation, not only at laboratory or test rig level, but
under demanding dispatching conditions at MHI validation plant in Japan shown in Figure 2.
Increased TIT cannot be successfully implemented in short time. Figure 1 includes the
introduction dates of Mitsubishi Large Gas Turbine Frames. The M501G went commercial in
1997, becoming the first gas turbine to apply steam cooling to a commercial engine. Today, 16
years later, MHI G fleet has become the largest and most successful steam cooled fleet with
59 units in operation featuring a six-year fleet reliability average of 98.62% (Reported by
Strategic Power Systems ORAP from Oct 2007 to Sept 2012). During these 16 years, the
original M501G has evolved to the M501G1 in 60Hz and to the M701G and M701G2 in
50Hz. This evolution was possible through progressive design enhancements addressing the

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engineering challenges involved in advanced technologies while targeting high reliability
required by today’s markets.

Figure 2. T-Point C/C Validation plant in Japan

After achieving a high degree of maturity in the steam cooled frame, the M501G1 installed in
T-Point was modified in 2009 to incorporate air cooled hardware while maintaining the same
TIT. This frame, which kept most of the features of the steam cooled predecessor, was called
M501GAC1 and added flexibility by eliminating the application of steam cooling. Once again,
a thorough validation process followed the GAC despite the fact that only the combustion
hardware had been modified from the original frame. Today, four years later, fourteen
M501GACs have been sold worldwide, including ten in North America.

The first three M501GAC units for the US market were manufactured and shipped from the
new Savannah Machinery Works in Georgia (refer to Figure 3) and are currently on base in
preparation for commissioning in 2014.

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 Figure 3. Savannah Machinery Works

In 2011, the M501GAC installed in T-Point was replaced with a new steam cooled frame
called M501J, which features the highest TIT currently available in the market (1,600 ºC)
with combined cycle efficiency in excess of 61%. This first unit has accumulated in excess of
10,000 AOH (Feb 2013) and it is being followed by the first of six single-shaft blocks for a
Japanese plant in Himeji, which is undergoing commissioning. This success has facilitated
sales of sixteen 60Hz and two 50Hz units (end of 2012). Upon accumulating operational
hours and following the successful approach applied in 2009 to the steam cooled G, an air
cooled version of the J, called JAC will be tested in 2014 to make it available for shipment in
2015.

The Japanese National Project

In 2004, MHI engaged in a Japanese Government Funded project called the “National
Project”. The main target of this project is the development of a 1,700°C (3,092°F) class gas
turbine in order to achieve 62-65% (LHV) combined cycle efficiency to reduce fuel
consumption and CO2 emissions. Figure 4 shows a sketch of the 1700ºC Class combined
cycle plant. The figure includes an exhaust gas recirculation line to reduce NOx emission with
high firing temperature.

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 Figure 4. Sketch of the future 1,700°C Plant

State-of-the-art technologies derived from the National Project include:

(1) Exhaust Gas Recirculation (EGR)

(2) Higher turbine cooling efficiency
(3) Lower thermal conductivity TBC
(4) Higher loading turbine aerodynamics
(5) Higher pressure ratio compressor and
(6) Advanced turbine material

Despite the fact that the above mentioned technologies were develop with the 1,700°C
concept in mind, they can be retrofitted into other frames that operate at lower temperatures,
enabling efficiency improvements of those units while facilitating progressive validation of
the new technology under temperatures lower than designed.

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M501J and M701J Concept

These new machines were designed to operate at 1,600 °C TIT, which is 100 °C higher than
the predecessor, the G-series. This frame features the largest power generation capacity and
highest thermal efficiency currently offered. Its features a 23:1 Pressure Ratio based on MHI’s
H-class 25:1 compressor and incorporated the following technologies from the Japanese
National Project:
- Advanced turbine cooling technology
- Advanced thermal barrier coating
- High Efficiency High Loading Turbine

Table 1 below shows the performance of the M501J and compares it with the M501GAC.

Table 1. Performance comparison

The J-series steam cooling design is based on the G-series steam cooling experience
accumulated in 59 operating units with more than 1.9 million actual operating hours and more
than 16,500 starts. Following the G reliable concept, the steam supply incorporates redundant
sources to maintain a steam cooling back-up source during all stages of operation. It also
maintains the basic structural design used in previous Mitsubishi large industrial gas turbines
including cold-end drive, two-bearing support, can-annular type combustor and 4 stage
turbine. Figure 5 below shows one 60Hz unit on base in preparation for commissioning.

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 Figure 5. One M501J installed on base

Future Commissioning Schedule

In addition to T-Point, 16 M501J have been sold in Asia (10 in Korea in 2:1 blocks and six in
Japan in 1:1 single shaft blocks). These units will be commissioned following the schedule in
Figure 6 below.

Figure 6. M501J Commissioning Schedule

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M501J Current Operating Experience

1. T - Point
The first unit installed in T-Point was commissioning in February 2011, just prior to the
terrible March 11, 2011 Tsunami/earthquake that affected Fukushima prefecture (refer to
Figure 7).

Figure 7. First M501J installed at T-Point

The output of T-Point with the new engine has been an important contributor to alleviate the
difficult condition of the Japanese power supply after most nuclear plants were shutdown.
Since commissioning of the M501J, T-Point has operated more than 10,000 AOH (Feb 2013)
and it has generated in excess of two GW – hr.

Several inspections of this first engine have been performed during low power demand
periods. The first inspection included lifting the rotor to remove the temporary
instrumentation and to assess the hot gas path parts condition after 100 hour sustained
operation at 1,600°C TIT. This and subsequent inspections have revealed good condition of
the hardware. Figure 8 shows the result of the most recent inspection performed after
accumulating more than 8,120 AOH.

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 Figure 8. Hardware excellent condition (inspection after 8,120 AOH and 101 starts)

2. Kansai Electric Power Co. Inc Himeji No.2 Power Station

Himeji No.2 Power Station is a state-of-the-art 2,900 MW station featuring six single shaft
blocks of 486.5 MW each with a Single Reheat Steam turbine that incorporates 50” Last Stage
Blades. The first unit started commissioning in November 2012 and is currently undergoing
load testing. The commissioning tests are progressing smoothly and the second unit, already
on-base is scheduled to start commissioning in the second quarter of 2013.

Modification of the T-Point unit to introduce the Air Cooled version M501JAC

Following the successful approach applied in 2009 to T-Point’s steam cooled M501G1, an air
cooled version of the current J will be tested in 2014 to make it available for shipment in 2015.
The extent of the modification will mimic the GAC experience, where air cooled liners will
be used and the steam supply lines will be isolated.

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Summary

 The introduction of new gas turbines that target high combined cycle efficiency involves
engineering challenges that cannot be achieved overnight. A reliable and efficient design
can only be achieved by applying a progressive and thorough design and validation
approach that involves years of operation under real world demanding conditions.

 Sixteen years after introducing steam cooling in T-Point, the G fleet has become the
largest and most successful steam cooled fleet, with an operational fleet of 59 units
featuring average reliability as high as or better than prior generation series such as the F
class.

 The air cooled version of the G was validated at T-Point from 2009 to 2011. It was then
replaced by the M501J. A total of fourteen M501GAC have been sold, including ten in
North America. Three of these units were manufactured in the state-of-the–art
manufacturing facility in Savannah Georgia and delivered to its project site in Virginia.

 The M501J was successfully introduced in T-Point and it has accumulated more than
10,000 AOH and one hundred starts, for a total generation in excess of 2 GW-hr.

 The second M501J is currently in advanced stage of commissioning and it is schedule to

go commercial later this year.

 A total of sixteen M501J and two M701J have been sold. The manufacturing of the first
50Hz units is ongoing and will be shipped in 2014.

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References

1. T. Ai, et al., 2009, “Development of an Air Cooled G class Gas Turbine” GT-2009-60321
ASME Turbo Expo 2009,
2. E. Ito, et al., 2009, “Development of Key Technologies for The Next Generation
1700C-class Gas Turbine” GT2009-59783 ASME Turbo Expo 2009,
3. Carlos Koeneke, Hisato Arimura, Junichiro Masada, Toshishige Ai, Takashi Kishine,
Hiroyuki HARA, “Development of a New 1,600ºC Turbine Inlet Temperature Large
Frame Gas Turbine for High Combined Cycle Efficiency”. PowerGen Europe 2010.

4. J Masada, T Ai , S Wakazono, T. Kishine, C. Koeneke and Y. Fukuizumi, 2012. “M501J

Validation Update”, Electric Power 2012.

5. J Masada, T Ai , S Wakazono, T. Kishine, C. Koeneke, 2012.”Mitsubishi 1,600ºC TIT J

Series Gas Turbine”, PowerGen Europe 2012.

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