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INDEX
CHAP. 1
Page
1. INTRODUCTION................................................................................................1-1
09-98-E P. 1-0
1. INTRODUCTION
A gas turbine is an internal combustion motive machine. From all points of view, it can
be considered as a self-sufficient system: in fact, it is capable to aspirate and compress
ambient air via its own compressor, to enrich the energetic power of air in its own
combustion chamber and to convert this power into useful mechanical energy during the
expanding process that takes place in its own turbine section. The resulting mechanical
energy is transmitted via a coupling to a driven operating machine, which produces work
useful for the industrial process in which the gas turbine belongs.
These applications are the subject of this traning course. They are intended for the
following industrial uses:
• Compressor drive
• Pump drive
09-98-E P. 1-1
These applications were the first ones to be introduced in terms of time. They
include the following fields:
• railways
• marine propulsion
• aviation
• road traction
The first gas turbines to be used in operating applications appeared on the market
at the end of the Forties; they were generally used in railways and presented the
advantage of burning liquid fuel, even of poor quality. In this regard, we will
mention the MS3001 turbine built by General Electric, with a power of 4500 HP,
which was used just for this purpose.
Successive achievements in material technology and extensive research into
combustion resulted in rapid improvements in performance, in terms of specific
power and efficiency, obtained by increasing maximum temperatures in the
thermodynamic cycle.
In this matter, three generations of evolution can be defined, distinguished by the
maximum temperature (°C) ranges of gases entering the first rotor stage of the
turbine:
09-98-E P. 1-2
Nuovo Pignone has built gas turbines of “heavy duty” type for industrial applications
since 1961. These are made in the Florence workshop under a Manufacturing
Agreement with General Electric, Schenectady - N.Y. - USA, which, in time, has
led to the acquisition of complete licences (MS5002 gas turbine) and to the
complete execution of some gas turbine models (turbines of the PGT range),
starting from engineering and on to all construction phases.
As a complement to their main activities, Nuovo Pignone converts gas turbines
intended originally for the aircraft industry into packages for industrial applications
which use the originary gas generator in conjunction with power turbines made
by General Electric (LM range), or by Nuovo Pignone (PGT16 and PGT25
ranges).
Since 1962 up to the present time, Nuovo Pignone has built about 1000 turbines,
complete with all auxiliaries required for their operation; of these, a good deal are
part of turnkey plants for all application purposes listed at para. 1.1.
09-98-E P. 1-3
In the following tables, gas turbines currently produced by Nuovo Pignone are divided
by model and by type of application.
_____________________________
(1)The values in the table refer to the turbine loading flange, under ISO conditions and
the use of natural gas.
09-98-E P. 1-4
_____________________________
(1) The values in the table refer to the turbine loading flange, under ISO conditions and the
use of natural gas.
09-98-E P. 1-5
Design Info
Compressor
• Two stage centrifugal compressor
• Pressure ratio 12.5:1
Combustion
• Single, combustion chamber
Turbine
• Two stage turbine
• Investment cast blades, forged discs
Package
• The complete Gen Set ismounted on a single baseplate
• The enclosure is integral with the baseplate providing maximum accessibility for gas
turbine and auxiliaries maintenance; noise level < 85dB (A) at 1m
• In outdoor applications the filter plenum is flanged on top of the enclosure
• The package design is standardized for quick delivery; custom applications can be
provided
• Package dimensions (including generators and filters) LxWxH = 5.5mx3.8mx2.3m;
Weight = 12t
Emissions Control
• Steam or water injection for standard combustion chamber
• Dry Low Emission configuration available to satisfy the most stringent environmental
regulations
Performance Info
Generator Drive (Expected Performance at ISO Conditions with fuel natural gas)
P. 1-4
INTRODUCTION
GE 5 (PGT 5)
Overview
The PGT5 heavy-duty gas turbine has been designed with modular concepts to facilitate accessibility and
maintainability.
The gas generator consists of a 15-stage, high efficiency, axial-flow compressor directly coupled to a single
stage turbine.
The low pressure shaft (two-shaft version) is a single-stage, high-energy turbine, with variable second stage
nozzles which grant maximum flexibility for mechanical drive service.
The PGT5 has a single combustion chamber system which is rugged, reliable and able to burn a wide range
of fuels, from liquid distillates and residuals to all gaseous fuels, including low BTU gas.
Typical applications include pump drive for oil pipelines and compressor drive for gas pipelines.
Design Info
Compressor
• Axial flow compressor, 15 stages
• Pressure ratio 9.1:1
Combustion
• Single, reverse flow combustion can
Turbine
Two shafts
• High Pressure turbine one reaction stage
• Low Pressure turbine one reaction stage
Package
• The gas turbine module on a single baseplate includes the engine, starting system, auxilia-
ries and acoustic enclosure
• Std. Configuration (excluding inlet/exhaust ducts/system):
• size 8mLxWxH = 8.5mx2.5mx3.0m
• weight 28 t
Emissions Control
• DLE combustion system
• Steam and water injection system
Performance Info
Generator Drive: Single Shaft version(Expected Performance at ISO Conditions with fuel natural gas)
Model Output Heat Rate Exhaust Flow Exhaust Temperature
PGT5 5220 kWe 13422 kJ/kWh 24.6 kg/s 524 °C
Mechanical Drive:Two Shafts version (Expected Performance at ISO Conditions with fuel natural gas)
Model Output Heat Rate Exhaust Flow Exhaust Temperature
PGT5 5450 kW 13450 kJ/kWh 25.8 kg/s 533 °C
P. 1-5
INTRODUCTIONS
GE 5B (PGT 5B)
Overview
The GE5B series is a 6 MW range industrial duty gas turbine designed in two configurations: A single shaft
configuration for power generation and a two shaft configuration for mechanical drive applications. The
completely new design of the GE5B combines the technology of aircraft engine design with the ruggedness
of the heavy duty PGT class of turbines. The flexibility, simplicity and compactness of the GE5B make it
ideal for industrial power generation, including steam production, Oil & Gas applications in remote areas
and Offshore installations. The control system is configured for fully automatic operation and has provisions
for connection to Remote Monitoring and Diagnostics. The GE5B is ideally suited for applications, which
require a continuous supply of electrical power with high availability and reliability. The exhaust energy is
enough to provide a substantial quantity of steam at various pressures and temperatures when coupled to a
Heat Recovery Steam Generator.
Design Info
Compressor
• Axial flow compressor, 11 stages
• First three stator stages are variable geometry
• Pressure ratio 15:1
Combustion
• Annular combustion chamber, 18 fuel nozzles
Turbine
• Two reaction stages
• First stage cooled
Package
• The gas turbine module on a single baseplate includes engine, starting system, load gear,
auxiliaries and acoustic enclosure
• The off-base equipment is limited to the lube oil coolers and electric generator
• The inlet filtration module is designed for mounting above the gas turbine enclosure
• The enclosure has wide double-joined doors allowing for ease of access to all turbine
components and auxiliaries or engine removal
• The package design is standardized for quick delivery; custom applications can be
provided
• Package dimensions (including filters on top of the enclosure)
LxWxH = 5.9mx2.5mx5.7m;Weight = 30t
Emissions Control
• The standard unit is configured with a DLE combustion system
Performance Info
Generator Drive (Expected Performance at ISO Conditions with fuel natural gas)
P. 1-6
INTRODUCTION
PGT 10A (two shaft)
Overview
The PGT10 is a high efficiency gas turbine designed and developed by Nuovo Pignone for shaft outputs
ranging between 9,500 and 15,000 HP at ISO conditions. Since first introduced to the market in 1988, the
PGT10 has met its design goals by providing customers with high performance and high reliability and
availability while keeping its design simplicity and easy maintenance concepts. To achieve high
efficiencies over an extended spectrum of power range, an uncommon combination of features has been
incorporated into the design: High pressure ratio, firing temperature level in line with second generation gas
turbines, variable axial compressor stator vanes and power turbine nozzles. The PGT10 combustion system
consists of a single combustion chamber designed for low NOx emissions and is suitable for a large variety
of gaseous and liquid fuels. Typical applications for PGT10 two-shaft gas turbines are not only natural gas
compression, centrifugal pump drive and process application, but also power generation as well as
Cogeneration and Offshore applications.
Design Info
Compressor
• Axial flow compressor, 17 stages
• Pressure ratio 14.1:1
Combustion
• Single combustion chamber
Turbine (Two shafts)
• High Pressure turbine two stages
• Low Pressure turbine two reaction stages
Package
• The gas turbine module on a single baseplate includes the engine and a load gear; the
auxiliaries are installed on a separate baseplate joined to that of the gas turbine to form a
single lift on which the sound-insulated enclosure is mounted
• The electric generator is installed on a concrete foundation to limit overall shipping
dimension
• The package design is standardized for quick delivery, but custom applications can be
provided
• Package dimensions (excluding generator and filters) 9.1mx2.5mx3.0m; Weight: 32t
Emissions Control
• The combustion system is available both in conventional and DLE configuration to
satisfy the most stringent environmental regulations
• Steam and water injection systems are available for NOx reduction and power augmenta-
tion
Performance Info
Generator Drive: Two Shaft version(Expected Performance at ISO Conditions with fuel natural gas)
Model Output Heat Rate Exhaust Flow Exhaust Temperature
PGT10 10220 kWe 11540 kJ/kWh 42.1 kg/s 484 °C
Mechanical Drive:Two Shafts version (Expected Performance at ISO Conditions with fuel natural gas)
Model Output Heat Rate Exhaust Flow Exhaust Temperature
PGT10 10660 kW 11250 kJ/kWh 42.3 kg/s 493 °C
P. 1-7
INTRODUCTIONS
GE 10B (single/two shaft) (PGT 10B 1/2)
Overview
The GE10 is a high efficiency and environmental friendly Heavy Duty Gas Turbine designed and developed
by Nuovo Pignone for Power Generation (including industrial co-generation) and Mechanical Drive appli-
cations.
Since it was first introduced to the market in 1988, the model PGT10A has been providing high perform-
ance, reliability and availability to worldwide customers while keeping with easy maintenance concepts.
From this starting point, in 1998 Nuovo Pignone launched on the market the high performance version of
this model with two different configurations:
Two shafts for mechanical drive and single shaft for power generation and cogeneration applications.
The GE10 Gas Turbine, with its ability to burn different fuels (natural gas, distillate oil, low BTU fuel), can
be installed in many countries with different environmental conditions: continental, tropical, offshore and
desert.
Continuous improvement of the model is carried out with reference to performance and emissions reduction
capability. In this context particular emphasis has been placed on the design of a DLN system for Nitrogen
Oxides (NOx) reduction in order to meet present and future standards for pollutant emissions.
Design Info
Compressor
• Axial flow compressor, 11 stages
• First three stages of stator are variable geometry
• Pressure ratio 15.5:1
Combustion
• Single combustion chamber
Turbine
Single shaft GE10/1 Two shaft GE10/2
• Three reaction stages • High Pressure turbine two reaction stages (cooled)
• First two stages cooled • Low Pressure turbine two reaction stages
Package
• The gas turbine module on a single baseplate includes the engine and the load gear; the auxiliaries
are installed on a separate baseplate joined to that of the gas turbine to form a single lift on which
the sound-insulated enclosure is mounted
• The electric generator is installed on a concrete foundation to limit overall shipping dimensions
• The package design is standardized for quick delivery; but custom applications can be provided
• Package dimensions (excluding generator and filters) LxWxH = 9mx2.5mx3; Weight = 40t
Emissions Control
• The combustion system is available both in conventional and DLN configuration to satisfy strin-
gent environmental regulations
• Steam and water injection systems are available for NOx reduction and power augmentation
Performance Info
Generator Drive: Single Shaft version(Expected Performance at ISO Conditions with fuel natural gas)
Model Output Heat Rate Exhaust Flow Exhaust Temperature
GE10 11250kW 11467 kJ/kWh 47.3 kg/s 490 °C
Mechanical Drive:Two Shafts version (Expected Performance at ISO Conditions with fuel natural gas)
Model Output Heat Rate Exhaust Flow Exhaust Temperature
GE10 11690 kW 11060 kJ/kWh 46.9 kg/s 487 °C
P. 1-8
INTRODUCTION
PGT 16
Overview
The PGT16 gas turbine is composed of the twin spool GE Aeroderivative LM1600 Gas Generator coupled
with a rugged, industrial power turbine designed by Nuovo Pignone.
The LM1600 Gas Generator is derived from the F404 turbofan aircraft engine, while the power turbine of the
PGT16 gas turbine is identical to the power turbine of the PGT10 Nuovo Pignone Heavy Duty, high effi-
ciency gas turbine, which has been in operation for more than half a million hours.
The power turbine shaft speed (7900 RPM) is optimized for direct coupling to pipelines and injection and
process centrifugal compressors with speed ranges that suit all operating conditions.
High efficiency and reliability are just two of a large number of benefits contributing to LM2500+ customer
value.
For generator drive applications the LM1600, coupled to its synchronous generator with a speed reduction
gear, is a highly flexible turbogenerator that can also cover combined cycle/cogeneration applications with
an electrical efficiency close to 50%.
Design Info
Compressor
• Twin spool axial compressor (3 stages LP compressor, 7 stages HP compressor)
• Pressure ratio 20.1:1
Combustion
• Annular combustion chamber (18 fuel nozzles)
Turbine
• Twin Spool Gas Generator turbine (1 stage HP turbine, 1 stage LP turbine)
• Two stages Power turbine (7900 RPM) with variable angle first stage nozzles
Package
• The complete gas turbine module is mounted on a single baseplate
• The enclosure is integrated with the baseplate providing maximum accessibility for gas
turbine and auxiliaries maintenance
• Standard Configuration (excluding inlet/exhaust ducts/system):
• Size LxWxH = 8.1mx2.5mx3.8m
• Weight 19t
Emissions Control
• Steam or water injection systems for NOx abatement
• Dry Low Emission (DLE) combustion system
Performance Info
Generator Drive: (Expected Performance at ISO Conditions with fuel natural gas)
Model Output Heat Rate Exhaust Flow Exhaust Temperature
PGT16 13735 kWe 10314 kJ/kWh 47.4 Kg/s 493 °C
Mechanical Drive: (Expected Performance at ISO Conditions with fuel natural gas)
Model Output Heat Rate Exhaust Flow Exhaust Temperature
PGT16 14252 kW 9756 kJ/kWh 47.4 kg/s 493 °C
P. 1-9
INTRODUCTIONS
PGT 25
Overview
The PGT25 gas turbine consists of the GE Aeroderivative LM2500 Gas Generator coupled with a rugged,
industrial power turbine designed by Nuovo Pignone. The LM2500 gas generator and the PGT25 power
turbine demonstrated the best overall performances to cover the 17,000-31,000 HP range with maximum
efficiency above 37%.
The speed of the output shaft, 6500 rpm, as well as the high capacity and simplicity of maintenance have
made the PGT25 highly suitable for driving direct coupled centrifugal compressors for pipeline service or
natural gas reinjection plants. Its light weight and high efficiency makes it well suitable for offshore and
industrial power generation.
The modular design, extended to all accessory equipment, takes into account the special requirements of
platform applications (minimum weights and overall dimensions), as well as drastically reduces erection
time and costs.
The gas generator can be easily dismantled with a simple translation within the package space, thus reduc-
ing the time required for maintenance.
Simplicity of construction and the high quality of the materials employed allow for long intervals between
overhauls and reduced maintenance costs.
Design Info
Compressor
• Sixteen stages axial compressor
• Pressure ratio 17.9:1
Combustion
• Annular combustion chamber (30 fuel nozzles)
Turbine
• Two stages Gas Generator turbine
• Two stages Power turbine (6500 RPM)
Package
• The complete gas turbine module comes mounted on a single baseplate
• The enclosure is integrated with the baseplate providing for maximum accessibility for gas
turbine and its auxiliaries maintenance
• Standard Configuration (excluding inlet/exhaust ducts/system):
• LxWxH = 9.1mx3.5mx3.7m ,Weight 38t
Emissions Control
• Steam or water injection systems for NOx abatement
• Dry Low Emission (DLE) combustion system
Performance Info
Generator Drive: (Expected Performance at ISO Conditions with fuel natural gas)
Model Output Heat Rate Exhaust Flow Exhaust Temperature
PGT25 22417 kWe 9919 kJ/kWh 68.9 Kg/s 525 °C
Mechanical Drive: (Expected Performance at ISO Conditions with fuel natural gas)
Model Output Heat Rate Exhaust Flow Exhaust Temperature
PGT25 23260 kW 9560 kJ/kWh 68.9 kg/s 525 °C
P. 1-10
INTRODUCTION
MS 5001
Overview
The MS5001 single shaft turbine is a compact heavy-duty turbine designed for long life and easy mainte-
nance.
The MS5001 gas turbine is the ideal solution for industrial power generation where low maintenance,
reliability and economy of fuel utilization are required.
Low investment costs make the MS5001 package power plant an economically attractive system for peak
load generation.
The MS5001 is ideally suited for cogeneration achieving very high fuel utilization indexes and allowing for
considerable fuel savings. Typical applications are industrial plants for cogeneration of power and process
steam or in district heating systems.
Design Info
Compressor
• Axial flow compressor, 17 stages
• Pressure ratio 10.5:1
Combustion
• Can-annular combustion, 10 chambers
Turbine
• 2 stages
• First stage nozzles cooled
Package
• Complete turbine package mounted on a single baseplate
• Enclosure integrated with the baseplate providing maximum accessibility for gas turbine
and auxiliaries maintenance
• Standard configuration (excluding inlet/exhaust ducts/system):
• size LxWxH = 11.6mx3.2mx3.7m;
• weight 87.5t
Emissions Control
• Steam or water injection systems for NOx abatement
• Dry Low NOx (DLN) combustion system
Performance Info
Generator Drive (Expected Performance at ISO Conditions with fuel natural gas)
P. 1-11
INTRODUCTIONS
MS 5002
Overview
The MS5002 gas turbine was launched in the 1970s and it has been updated and up-rated along the years to
match the higher power demand.
Presently two versions are available:
MS5002C - 38000 HP at ISO condition
MS5002D - 43700 HP at ISO condition.
The MS5002 is a gas turbine specifically designed for mechanical drive applications with a wide operating
speed range to meet operating conditions of the most common driven equipment, centrifugal compressors
and pumps. It also has the capability to burn a large variety of gaseous and liquid fuels.
Almost 500 units (more than 300 of which were manufactured by Nuovo Pignone) have been installed
world-wide in all possible environments including arctic, desert, offshore, etc., always demonstrating easy
operability as well as very high reliability and availability. The simple design and robustness of the ma-
chine allow for complete maintenance to be performed on site without the need for special tools or service
shop assistance. Typical applications include Gas Boosting, Gas Injection/Reinjection, Oil & Gas Pipelines,
LNG plants and Gas Storage
Design Info
Compressor
MS5002C
• Sixteen stages axial compressor
• Pressure ratio 8.9:1
MS5002D
• Seventeen stages axial compressor
• Pressure ratio 10.8:1
Combustion
• Reverse flow, multi chamber (can-annular) combustion system (12 chambers)
Turbine
• Single stage Gas Generator turbine
• Single stage power turbine (4670 RPM rated speed) with variable angle nozzles.
Package
• Two baseplates configuration (gas turbine flange to flange unit and auxiliary system.
• Enclosures integrated with the baseplates providing maximum accessibility for gas turbine
and auxiliaries maintenance
• Standard configuration (excluding inlet/exhaust ducts/system):
• size LxWxH = 15.0mx3.2mx3.8m
• weight 110t
Emissions Control
• Steam or water injection systems for NOx abatement
• Dry Low NOx (DLN) combustion system
Performance Info
Mechanica Drive (Expected Performance at ISO Conditions with fuel natural gas)
Model Output Heat Rate Exhaust Flow Exhaust Temperature
MS5002C 28340 kW 12310 kJ/kWh 126.0 kg/s 515 °C
MS5002D 32590 kW 11900 kJ/kWh 141.3 kg/s 510 °C
P. 1-12
INTRODUCTION
PGT 25+
Overview
The PGT25+ gas turbine has been developed for 30 MW ISO shaft power service with the highest thermal
efficiency level (approx. 40%).
The PGT25+ gas turbine consists of the GE Aeroderivative LM2500+ Gas Generator (updated version of
LM2500 gas generator with the addition of zero stage to axial compressor) coupled with a 6100 RPM Power
Turbine. Built on the LM2500 heritage and with demonstrated 99.6% reliability, the PGT25+ incorporates
proven technology improvements and a large percentage of parts in common with LM2500 in order to
deliver the same outstanding level of reliability. Designed for its ease of maintenance, the PGT25+ also
provides a high level of availability.
High efficiency and reliability are just two of large number of benefits contributing to PGT25+ customer
value.
Application flexibility makes the PGT25+ ideal for a range of mechanical drive (gas pipeline etc.), power
generation, industrial cogeneration and offshore platform applications in any environment.
Design Info
Compressor
• Seventeen stages axial compressor
• Pressure ratio 21.5:1
Combustion
• Annular combustion chamber (30 fuel nozzles)
Turbine
• Two stage Gas Generator turbine
• Two stage Power turbine (6100 RPM)
Package
• Gas Generator, Power Turbine and auxiliary System mounted on a single baseplate
• The enclosure is integrated with the baseplate providing maximum accessibility for gas
turbine and auxiliaries maintenance
• Standard Configuration (excluding inlet/exhaust ducts/system):
• size LxWxH = 6.5mx3.6mx3.9m (gas turbine and auxiliary baseplate)
• weight 38t (gas turbine and auxiliary baseplate)
Emissions Control
• Steam or water injection systems for NOx abatement
• Dry Low Emission (DLE) combustion system
Performance Info
Generator Drive: (Expected Performance at ISO Conditions with fuel natural gas)
Model Output Heat Rate Exhaust Flow Exhaust Temperature
PGT25+ 30226 kWe 9084 kJ/kWH 84.3 Kg/s 500 °C
Mechanical Drive: (Expected Performance at ISO Conditions with fuel natural gas)
Model Output Heat Rate Exhaust Flow Exhaust Temperature
PGT25+ 31360 kW 8754 kJ/kWh 84.3 kg/s 500 °C
P. 1-13
INTRODUCTIONS
MS 6001
Overview
The MS6001 is a single shaft heavy-duty gas turbine. Its design was based on the well proven mechanical
features of the MS5001 in order to achieve a compact, high efficency unit.
The MS6001 is widely applied in power generation applications for base, mid-range and peak load service.
Other typical applications include driving of process machines, such as compressors, in LNG plants.
Combined cycle plants based on MS6001 achieve very high efficiencies with higher availability and
reliability than conventional thermal plants.
Design Info
Compressor
• Axial flow compressor, 17 stages
• Pressure ratio 11.9:1
Combustion
• Can-annular combustion, 10 chambers
• Dual fuel capability
Turbine
• 3 stages, first two cooled buckets
• First 2 stage nozzles cooled
Package
• Complete turbine package mounted on a single baseplate
• Enclosure integrated with the baseplate providing for maximum accessibility for gas
turbine and its auxiliaries maintenance
• Standard configuration (excluding inlet/exhaust ducts/system):
• size LxWxH = 15.9mx3.2mx3.8m;
• weight 96t
Emissions Control
• Steam or water injection systems for NOx abatement
• Dry Low NOx (DLN) combustion system
Performance Info
Generator Drive: (Expected Performance at ISO Conditions with fuel natural gas)
Model Output Heat Rate Exhaust Flow Exhaust Temperature
MS6001B 42100 kWe 11230 kJ/kWh 145.8 kg/s 552 °C
Mechanical Drive: (Expected Performance at ISO Conditions with fuel natural gas)
Model Output Heat Rate Exhaust Flow Exhaust Temperature
MS6001B 43530 kW 10825 kJ/kWh 145 kg/s 544 °C
Experiences
• More than 46 units sold
P. 1-14
INTRODUCTION
LM 6000
Overview
The GE LM6000 delivers more than 44.8 MW of power at over 42.7% thermal efficiency.
It is the world’s most fuel-efficient, simple-cycle gas turbine. High efficiency, low cost and easy installation
make the LM6000 the perfect modular building block for electrical power applications such as industrial
cogeneration of utility peaking, both midrange and base-load operations. As an aircraft engine aboard the
Boeing 747, the LM6000 has logged more than 10 million flight hours, with the lowest shop visit rate of
any jet engine.
Continuing the tradition of GE’s LM6000 established record, the LM6000 is ideal as a source of drive-
power for pipeline compression, offshore platforms, gas reinjection and LNG compressors. The LM6000 has
been GE’s first aeroderivative gas turbine to employ the new Dry-Low Emission premixed combustion
system; this system is retrofittable on LM6000’s already in operation. Water or steam injection can also be
used to achieve low NOx emissions.
Design Info
Compressor
• Low pressure compressor 5 stages
• High pressure compressor 14 stages
• Pressure ratio 30:1
Combustion
• Annular combustion chamber
Turbine
• High Pressure turbine 2 stages
• Low Pressure turbine 5 stages
Package
• Gas Generator, Power Turbine and auxiliary system mounted on a single baseplate
• The enclosure is integrated with the baseplate providing maximum accessibility for gas
turbine and auxiliaries maintenance
• Standard configuration (excluding inlet/exhaust ducts/system):
• size LxWxH = 9.3mx4.2mx4.4m
• weight 31t
Emissions Control
• Steam or water injection system for NOx abatement
• Dry Low Emission (DLE) combustion system
Performance Info
Generator Drive: (Expected Performance at ISO Conditions with fuel natural gas)
Model Output Heat Rate Exhaust Flow Exhaust Temperature
LM6000 43076 kWe 8707 kJ/kWh 131 Kg/s 450 °C
Mechanical Drive: (Expected Performance at ISO Conditions with fuel natural gas)
Model Output Heat Rate Exhaust Flow Exhaust Temperature
LM6000 44740 kW 8455 kJ/kWh 127 kg/s 456 °C
P. 1-15
INTRODUCTIONS
MS 7001
Overview
The MS7001EA is a single shaft heavy-duty gas turbine for power generation and industrial applications
requiring the maximum reliability and availability.
With design emphasis placed on energy efficiency, availability, performance and maintainability, the
MS7001EA is a proven technology machine with more than 500 units of its class in service.
Typical applications in addition to the 60Hz power generation service are large compressor train drives for
LNG plants.
Design Info
Compressor
• Seventeen stages axial compressor
• Pressure ratio 12.5:1
Combustion
• Reverse flow, multi chamber (can-annular) combustion system (10 chambers)
Turbine
• Three stages turbine (3600 RPM)
Package
• Two baseplates configuration (gas turbine flange to flange unit and auxiliary system)
• Enclosures integrated with the baseplates providing maximum accessibility for gas turbine
and auxiliaries maintenance
• Standard configuration (excluding inlet/exhaust ducts/system):
• size LxWxH = 11.6mx3.3mx3.8m
• weight 121t
Emissions Control
• Steam or water injection systems for NOx abatement
• Dry Low NOx (DLN) combustion system
Performance Info
Generator Drive: (Expected Performance at ISO Conditions with fuel natural gas)
Model Output Heat Rate Exhaust Flow Exhaust Temperature
MS7001EA 85100 kWe 11000 kJ/kWh 300 kg/s 537 °C
Mechanical Drive: (Expected Performance at ISO Conditions with fuel natural gas)
Model Output Heat Rate Exhaust Flow Exhaust Temperature
MS7001EA 81590 kW 11020 kJ/kWh 278 kg/s 546 °C
P. 1-16
INTRODUCTION
MS 9001
Overview
The MS9001E is a single shaft heavy-duty gas turbine. It was developed for generator drive service in the 50
Hertz market.
The MS9001E is widely applied in power generation for base, mid-range and peak load service.
Combined cycle plants based on MS9001E achieve very high efficiencies with higher availability and
reliability than conventional thermal plants.
Design Info
Compressor
• Axial flow compressor, 17 stages
• Pressure ratio 12.6:1
Combustion
• Can-annular combustion, 14 chambers
• Dual fuel capability
Turbine
• 3 stages, first two cooled buckets
• First 2 stage nozzles cooled
Package
• Two baseplates configuration (gas turbine flange to flange unit and auxiliary system)
• Enclosures integrated with the baseplates providing maximum accessibility for gas turbine
and auxiliaries maintenance
• Standard configuration (excluding inlet/exhaust ducts/system):
• size LxWxH = 22.1mx4.5mx6.3m
• weight 217.5
• Emissions Control
• Steam or water injection systems for NOx abatement
• Dry Low NOx (DLN) combustion system
Performance Info
Generator Drive: (Expected Performance at ISO Conditions with fuel natural gas)
Model Output Heat Rate Exhaust Flow Exhaust Temperature
MS9001E 123400 kWe 10650 kJ/kWh 412.8 kg/s 543 °C
Experiences
• 44 Units sold
P. 1-17
INTRODUCTIONS
TYPE POWER MAX EFFiCIENCY
GE 2 2,0MW 25 %
GE 5 B 5,9 - 6,2 MW 32 %
MS 6001 B 42 MW 32,5 %
P. 1-18
INTRODUCTION
g Nuovo Pignone
INDEX
CHAP. 2
Page
09-98-E P. 2-0
Fig. 2.1 shows an example of a gas turbine (in this specific case, it is our MS6001 gas
turbine) with a sectional view of the machine properly said. This figure has the purpose
to highlight the main component parts involved in the operating cycle.
AUSILIARI
AUXILIARIES FLANGIA-FLANGIA
FLANGE TO FLANGE
BASAMENTO
BASEPLATE
• auxiliary equipment
• baseplate
The above systems are completed by the suction, exhaust and control systems,
which, like the auxiliary equipment and the baseplate, are dealt with in the relevant
chapters, whereas here only details about their arrangement and interface with the
flange-flange assembly (Fig. 2.1) are described.
In fact, this chapter deals exclusively with the operating principles of a flange-
flange.
09-98-E P. 2-1
• it increases the energy level of compressed air by the addition of fuel gas
which undergoes combustion in a combustion chamber;
• it directs high pressure and high temperature air to a turbine section, which
converts thermal energy into mechanical energy that makes the shaft
revolve; this serves, on the one hand, to supply useful energy to the driven
machine, coupled to the machine by means of a coupling and, on the other
hand, to supply energy necessary for air compression, which takes place in
a compressor connected directly with the turbine section itself;
• it expels low pressure and low temperature gases resulting from the above-
mentioned converting process into the atmosphere.
Fig. 2.2 overleaf shows the behavioral pattern of pressures and temperatures, in
terms of quality, inside the different machine sections corresponding to the above-
mentioned operating phases.
09-98-E P. 2-2
Fig. 2.2
09-98-E P. 2-3
Fig. 2.2 enhances the fact that combustion takes place under almost constant
pressure conditions.
Unlike alternative motors, compression and expansion take place on a continual
basis, as happens for power generation.
On the contrary, in an alternative motor (for ex., a four-stroke, eight cycle motor),
though power is generated in the expansion phase, like in a turbine, this process
takes only 1/4 of the complete cycle, whereas in a gas turbine expansion takes place
continually all through the cycle. The same applies to compression.
For the same reason, along with the fact that there are no masses in alternate
motion, the degree of regularity of the running cycle of a gas turbine is incomparably
greater than that of an alternative motor (eight or Diesel cycle).
A gas turbine (Fig. 2.3) is composed of three main sections, described in the following
paragraphs. As concerns design and construction features, these are extensively dealt with in
Chapter 3.
09-98-E P. 2-4
2.2.1 Compressor
The compressor shall be of the axial type (Fig. 2.3). The choice of this type
of compressor depends on the fact that this compressor is capable to deliver
high air output ratings, necessary to obtain high values of useful power in a
reduced size. This concept will be resumed later, when the main
thermodynamic ratios in the operating cycle of a gas turbine are described.
At the compressor output side there are a few stages of Exit Guide Vanes or
EGV, necessary to obtain maximum pressure recovery before air enters the
combustion chamber.
The compressor serves also to supply a source of air needed to cool the walls
of nozzles, buckets and turbine disks, which are reached via channels inside
the gas turbine, and via external connecting pipings. Additionally, the
compressor supplies sealing air to bearing labyrinth seals.
09-98-E P. 2-5
In the case of "heavy duty" gas turbines as the one shown in Fig. 2.3, the
combustion section consists of a system of one or more tubular combustion
chambers (in this specific case there are ten combustion chambers) arranged
symmetrically and evenly in a circumference; these chambers receive and
burn fuel by means of an equal number of burners (one per combustion
chamber).
Air enters each chamber with a flow direction inverse to that of the hot gases
inside (for this reason, this method of air distribution is called "reverse
flow"). This external flow, which marginally touches the various chambers,
serves to cool them. In addition, the part of air that does not take part in the
combustion process is used for cooling the combustion products; in fact, it
is introduced into the chambers through “diluition” holes until optimal
temperature conditions are established to allow the gas and air mixture into
the turbine section.
Air passage from the combustion section properly said to the gas turbine
inlet takes place inside manifolds called “transition pieces”; here, the gases
flowing out of the single combustion chambers are led to form a continuous
annular profile, equal to the one that leads into the first stage nozzles ring.
Initially, the combustion process is ignited by one or more spark plugs. Once
ignited, combustion proceeds in a self-sufficient way without the help of
spark plugs, as long as the delivery conditions of fuel and combustion air are
fulfilled.
In the case of gas turbines built for the aviation industry (LM , PGT16 and
25 range), the combustion section consists of a single chamber of toroidal
shape, with direct and not "reverse flow" cooling; in fact, this helped reduce
external diametral sizes, since a smaller frontal section was needed in order
to offer as little resistance as possible to aircraft motion.
For the same reason, this combustion chamber does not need any separate
transition pieces. The other operating principles are the same as those
described for tubular chambers.
09-98-E P. 2-6
In the case of "heavy duty" turbines, as shown in Fig. 2.1, the turbine section
comprises a certain number of stages (in this specific case, three stages), each
one of them consisting of one stator stage (distributor nozzle); in this stage,
high temperature and high pressure gases delivered by the transition piece
described beforehand are accelerated and directed towards the rotor stage of
buckets mounted on a disk connected with the power shaft.
As mentioned before (para. 2.1), the conversion of thermal energy and
pressure into kinetic energy takes place in the stator stage.
The rotor stage completes this conversion, as here kinetic energy is
transformed into energy that drives the shaft, thus generating the power
required to drive the compressor (internal compression work, cannot be used
as externally useful work) and to operate the driven machine (generator,
compressor, etc.) connected to the gas turbine by means of a coupling.
The energy of gases supplied by the combustion system can be varied by
changing the delivery rate of fuel. In this way you can regulate the useful
power values needed for the technological process of which the gas turbine
is the motor.
Air enters the compressor at point (1), which represents ambient air conditions. These
conditions are classified according to pressure, temperature and relative humidity values.
09-98-E P. 2-7
It was agreed that standard design conditions be classified as ISO Conditions, to which there
correspond the following reference values:
ISO CONDITIONS
Afterwards, air is compressed inside the compressor, and exits in the condition indicated at
point (2). During the converting process from (1) to (2), no heat is released outside. However,
air temperature increases, due to polytropic compression, up to a value variable depending on
gas turbine model and ambient temperature.
After leaving the compressor, air enters the combustion area, practically under the same
pressure and temperature conditions as at point (2) (except for losses undergone on the way
from the compressor delivery side to the combustion chamber inlet, which amount to about 3
to 4% of the absolute value of delivery pressure). Fuel is injected into the combustion chamber
via a burner, and combustion takes place at practically constant pressure.
Conversion between points(2) and (3) represents not only combustion. In fact, the temperature
of the combustion process properly said, which takes place under virtually stechiometric
conditions, reaches excessively high values (around 2000 °C) locally in the combustion area
next to the burner, due to the resistance of materials downstream.
Therefore, the conversion final temperature, relative to point (3), is lower, as it is the result of
primary gases mixing with cooling and dilution air as described previously.
In this regard, it is useful to give some definitions of temperature at point (3), which is the
maximum cycle temperature or firing temperature (see Fig. 2.5).
09-98-E P. 2-8
Section A refers to the so-called "turbine inlet temperature", which is the average
temperature of gases in plane A.
Section B refers to the so-called “firing temperature”, which is the average gas
temperature in plane B.
Section C refers to the so-called “ISO firing temperature", which is the average gas
temperature in plane C, calculated as a function of the air and fuel flow rates via
a thermal balance of combustion according to the ISO 2314 procedure.
The difference in the interpretation of temperatures in sections A and B consists
in the fact that, on gas turbines like those which we are dealing with in this training
course, in section B we take into account the mixture of 1st stage nozzle cooling
air, which was not involved in the combustion process, but mixes with burnt gases
after cooling the surface of the nozzle.
According to the Nuovo Pignone - General Electric standard, the temperature that
best represents point (3) is the one in section B.
09-98-E P. 2-9
The following transformation, comprised between points (3) and (4), represents
the expansion of gases through the turbine section, which, as mentioned before,
converts therma energy and pressure into kinetic energy and, thanks to the
revolutions of the power shaft, into work used for compression (internal, not
useable) and external useful work, thanks to the connection with an operating
machine.
Over 50% of the energy developed by expansion in the gas turbine is absorbed by
the axial compressor for its compressing work.
Downstream of section (4), gases are exhausted into the atmosphere.
The thermodynamic representation of the events described so far is visible in Fig.
2.6 (pressure diagrams - volume P-V and temperature - entropy T-S).
In the cycle illustrated in the above figure, the 4 points correspond to the same
described before.
In particolar, note the compression and expansion transformations, obviously
these are not isoentropic.
In this respect, please remember that:
the specific compression work Wc , from (1) to (2), is expressed with good
approximation by the following ratio:
the specific expansion work Wt , from (3) through (4), is expressed by:
Heat Q1, supplied to the combustion chamber from (2) to (3), is expressed by:
09-98-E P. 2-10
The gas turbine cycle "closes" ideally with the transformation from (4) to (1),
which corresponds to the cooling of exhaust gases, in that heat Q2 is aspirated out
into the atmosphere, as though the latter were a refrigerant of infinite capability.
The thermodynamic ratio that describes the cooling process of exhaust gases is
the following:
Q2 = Cpm(T4-T1) • (T4-T1) (Kj/Kggas.)
The various values for Cpm, expressed in the preceding ratios, represent the average
specific heat at constant pressure between the extreme temperature values in the
interval examined.
For a more rigorous evaluation, it would be necessary to proceed by means of
integral calculation.
Once Q1, Q2, Wc and Wt, are known, you can obtain the valuesforthe following
significant parameters:
So far, all descriptions and examples refer to a single shaft turbine like MS 6001.
In fact, in the diagram illustrated in Fig. 2.4, the entire turbine section is connected
mechanically witht the axial compressor.
Such types of single shaft turbines are suitable for driving operating machines that
run at constant speed, such as alternators and, for this reason, are used typically in
the generation of electric energy.
In applications, in which power regulation is achieved by means of speed variation
in the driven machine, two-shaft gas turbines are usually employed (see diagram
in Fig. 2.7); in this case, the turbine is divided into two mechanically separate
sections:
• A high pressure section, which runs at constant speed within a wide range
of powers, and drives exclusively an axial compressor.
• A low pressure section, connected with the operating machine via a coupling;
this section can vary its running speed independent of the high pressure
turbine section.
09-98-E P. 2-11
This configuration, with the addition of other elements which will be described in
Chapter 4, serves to regulate the driven machine speed without the need to vary the
speed of the axial compressor; thus, the latter may continue to run at its design
speed, with optimal efficiency.
09-98-E P. 2-12
09-98-E P. 2-13
A gas turbine uses ambient air, therefore, its performance is greatly affected by all
factors that influence the flow rate of air delivered to the compressor, in terms of
weight.
These factors are:
• Temperature
• Pressure
• Relative humidity
In this regard, we remind you that reference conditions for the three above-
mentioned factors are, by convention, ISO standards (para. 2.3).
09-98-E P. 2-14
HR = Q1/Nu
CORRECTION
FACTOR
ATMOSPHERIC
PRESSURE CORRECTION
FACTOR
ATMOSPHERIC
PRESSURE
Fig. 2.10
09-98-E P. 2-15
Relative humidity influences the specific weight of air aspirated by the compressor.
In fact, humid air is less dense than dry air, so if the relative humidity increases,there
decreases the power output and there increases specific consumption (HR) (Fig.
2.11).
In the past, such an effect used to be neglected. Nowadays, as ever more powerful
gas turbines are made and humidity is added in the form of water or steam by
reduction of NOx, this effect must be taken into consideration.
Fig. 2.11
Next to the three “external” factors described in the preceding paragraph, there are
other factors which notably affect the performance of a gas turbine. These may be
called “internal” factors, because they are related to the auxiliary systems of the gas
turbine.
They are the following:
09-98-E P. 2-16
09-98-E P. 2-17
Gaseous fuels with a lower calorific value than natural gas (commonly called "low
btu gases") can greatly influence the performance of a gas turbine.
In fact, if the calorific value diminishes (Kj/Nm3), the weight of fuel delivered to
the combustion chamber must increase to provide the necessary amount of energy
(Kj/h).
This addition in the weight of the fluid, which is not even compressed by the
compressor, provokes an increase in power (see the definition of useful work at
para. 2.3) and a reduction in specific consumption.
In this case, the power absorbed by the compressor is left substantially unvaried.
However, in the case of combustion of “low btu gases”, the following side effects
must be taken into consideration:
09-98-E P. 2-18
Fig. 2.12
09-98-E P. 2-19
09-98-E P. 2-20
Fig. 2.13 shows the typical effects of steam injection on the output power of a gas
turbine (in this case, an MS 5002 gas turbine) as a function of ambient temperature.
09-98-E P. 2-21
Evaporative cooling
Curves in fig. 2.9 show clearly how power and efficiency increase as the
compressor inlet temperature decreases.
The latter can be reduced artificially by using an evaporative cooler located
upstream of the suction filter.
Water, fractioned into drops or in the form of a liquid film, cools the air by
evaporating in the cooler as it flows in contrary direction, thus originating an
adiabatic-isoenthalpic exchange (see fig. 2.14).
EVAPORATION CELLS
CELLE AD EVAPORAZIONE
H20 HEADER
COLLETTORE H2O
COALESCER/DEMISTER
COALESCER/DEMISTER
H 0 CIRCULATING
POMPA
2
H2O
DI CIRCOLAZIONEPUMP
SUMP TANK
SUMP TANK
In order to prevent water from being drawn towards the compressor and fouling it,
downstreams of the cooler there are one or more stages of drop separators
(demisters), which, by inertia, separate any water drops that might be carried away
downstream of the cooler by the flow of air aspirated by the turbine.
Fig. 2.15 shows the effects of evaporative cooling on the gas turbine output power
and specific consumption.
As can be noted, benefits increase as relative humidity decreases and ambient
temperature increases.
Unfortunately, the above requirements are met in environments (for example,
deserts), in which water is not always available in the amounts needed by the
cooler.
09-98-E P. 2-22
Inlet chilling
In environments in which a high degree of average relative humidity is present
(higher than 60%) and ambient temperatures are not excessively high, it is
advisable to cool air with a different method, commonly called "inlet chilling";
according to this method, air is cooled during a refrigerating cycle (based generally
on absorption) carried out in a closed circuit. In this way, the restrictions imposed
by relative humidity and by ambient temperature, described in the preceding
system, can be eliminated. The minimum temperature reached by air at the end of
the cooling process is strictly dependent on the capability of the refrigerating cycle
to produce cold liquid and on the efficiency of the thermal exchange that takes
place in the water - air exchanger.
Figure 2.16 shows an operating diagram of this system (in this example, steam
is used for the absorption cycle), composed of a chiller, water connecting pipings
and a water - air exchanger, installed downstream of the gas turbine suction filter.
Same as in evaporative cooling, also in this case it is necessary to install a
coalescer/demister downstream of the system, in order to prevent humidity from
reaching the compressor inlet section.
09-98-E P. 2-23
DEMISTER/COALESCER
DEMISTER/COALESCER
SCAMBIATORE
HEAT EXCHANGER
DRAIN
DRENAGGIO
COOLING WATER INLET
INGRESSO ACQUA FREDDA
CHILLER
CHILLER RITORNO ACQUA DA RAFFREDDARE
Figure 2.17 shows a comparison between the cooling powers of the two systems.
% RH const. lines
Saturation line
d
PSYCHROMETRIC
CHART
constant moisture content line
a Kgwater/Kgair
b
c
constant enthalpy line
Tc Tb Td Ta
09-98-E P. 2-24
09-98-E P. 2-25