THE AMERICAN SOCIETY OF MECHANICAL ENGINEERS

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Copyright © 1990 by ASME

Development of a New 25MW High Efficiency

Heavy-Duty Gas Turbine H-25
HARUO URUSHIDANI
Deputy Manager, Thermal Power Plant Design Department
TETSUO SASADA
Engineer, Gas Turbine Design Section
Hitachi Works
MASAMICHI WADA
Manager, Power Generation & Delivery Division
KAZUHIKO KAWAIKE
Senior Researcher, Mechanical Engineering Research Laboratory
Hitachi, Ltd.
Tokyo and Hitachi, Japan

ABSTRACT
INTRODUCTION
A new 25MW class gas turbine H-25 has been The H-25 gas turbine features high thermal
developed to meet both 50 Hz and 60 Hz power efficiency of over 32% (LHV), with a turbine inlet
generation needs with high reliability and efficient temperature of 1260 ° C and a pressure ratio of 14.7.
performance utilizing advanced high temperature gas Figure 1 shows performance diagrams surveyed for the
turbine technologies. Because of its superior selection of cycle conditions. Since the thermal
performance, over 32% in simple cycle efficiency, the efficiency of gas turbines is highly dependent on the
H-25 gas turbine enables significant reduction of turbine inlet temperature and the pressure ratio,, the
fuel consumption compared with previous 25MW class optimum cycle conditions were selected based on the
turbines. The H-25 also achieves higher thermal diagrams [1]. The cycle conditions of the H-25 were
efficiency in a combined cycle power plant and a selected for both high specific power and high
cogeneration plant with a waste heat recovery boiler. thermal efficiency in simple-cycle operation and also
The first unit entered commercial operation at the for high combined-cycle or cogeneration thermal
end of November 1988 after full load factory test efficiency.
instrumented with more than 800 pieces of The H-25 has the following features
instrumentation. •' Generator terminal thermal efficiency of
This paper describes the design features and the over 32% (LHV) in simple-cycle operation.
latest technological refinements in each component of • Heavy-duty design for industrial use,
the H-25 gas turbine. Also presented are the permitting long term continuous operation.
component test programs and the results of full load • Good maintainability.
factory test and field test on the first unit.

48
34 Simple cycle 47 Combined cycle
o precooled cooling system H-25 design point o precooled cooling system
> 33 _--- --^ 5 46 Pressure ratio

° 14 —__— --^ H-25 design point

4
325 ' ' 16 14 12
o
44 '
1300
30 d 1 43 1200
2. 10 -- j
29 1000 11001200
" 42 1100
1300
F 29 Turbine inlet temperature (°C) 41 Turbine inlet temperature (°C)
1000
27 40
150 200 250 300 3_ 300 350 400 450 500
Specific power kW/kg.s Specific power kW/kg.s

Fig. 1 Gas Turbine Performance

*Presented at the Gas Turbine and Aeroengine Congress and Exposition—June 11-14, 1990—Brussels, Belgium

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 Fia. 2 H-25 Gas Turbine Cross Section

OVERALL DESIGN

• Fuel flexibility from light distillate oil Figure 2 shows a cross section of the H-25 gas
and crude oil to natural gas. turbine. It is a single-shaft type heavy-duty gas
• Modular design requiring minimum field turbine, exclusively for power generation. The
installation. rotational speed is of 7280 RPM and the use of
• High cogeneration efficiency when combined reduction gearing enables it to drive both 50 Hz and
with a heat-recovery steam generator. 60 Hz generators. The rotor is a fully stacked
• Performance enhancement for existing MS5001 construction supported by two tilting-pad-type
gas turbine plants, through replacement with bearings. The thrust bearing is located on the
H-25 turbines. compressor end with eight shoes on both sides of the
The Table I shows principal specifications of bearing runner.
the H-25 gas turbine. Using natural gas as fuel, The compressor is a 17-stage axial type with
output at the generator terminals is 23,500 kW, with high pressure ratio, and the combustion system
a thermal efficiency of 32.3% (LHV). The H-25 is consists of 10 combustors with effective cooling
also available with an optional pre-cooling system construction for high firing-temperature operation.
which reduces cooling air temperature for the turbine The turbine has three stages designed with advanced
nozzle and bucket via an inter-cooler. With this cooling technologies [2].
system, output can be increased approximately 15%. A portion of the compressor discharge air is
used to cool the first and second-stage buckets and
first-stage nozzle. When the optional inter-cooler
is used, this air is extracted from the compressor
TABLE I Specifications of H-25 Gas Turbine discharge and cooled by the external air cooler, then
led into the turbine to cool the blades. The second-
stage nozzle and wheel space are cooled by the 11th
Type Standard type compressor extraction air, and third-stage nozzle and
With inter-
Specifi- (Without inter- wheel space are cooled by the 6th compressor
cooler
cation cooler) extraction air. Figure 3 shows the cooling circuit.
The horizontally split casings are adopted to
Fuel Natural gas Natural gas
facilitate field maintenance.
Output (kW) 23,500 26,770
Heat rate 2661 2637
(kcal/kW-h) (LHV)
Air flow (kg/s) 88 88
Exhaust 530 550
temperature (°C)
Rotating speed 7280
(r/mir.)
Compressor Axial type, 17 stages
Turbine Axial type, 3 stages
Combustor Reverse flow, 10 cans

Note: Performance is net value at the generator

terminals and includes 3.5" H2O inlet and 11th stage Compressor discharge
2.5" H2O exhaust pressure drops at ISO
standard ambient condition. Fig. 3 Cooling Circuit

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COMMENT TECHNOLOGY
Compressor
The H-25 compressor is a 17-stage axial
compressor, which achieves a pressure ratio of 14.7
by applying a high rotational speed design approach.
Figure 4 shows a photograph of the compressor. A
variable inlet guide vane (VIGV) and selective bleeds
at the 6th and 11th stages provide an adequate surge
control during start-up. The corrected speed control
of the VIGV and bleed valves accomplishes an optimum
start-up sequence according to ambient temperature
variances. The extraction air flows at 6th and 11th
are supplied to the 2nd and 3rd turbine stages for
the nozzle and wheel space cooling.
The H-25 compressor aerodynamic and mechanical
design is basically a scale-up design of a 17-stage
model compressor [3]. This model compressor was made
prior to the development of the H-25 and installed at
Hitachi's Gas Turbine Development (GTD) center, as an
air source for combustion test facilities. The
aerodynamic performance and the dynamic behavior of
, customers' needs.
the compressor, such as surge margin, rotating stall
and blade dynamic stress, were confirmed through the
test of this model compressor. The reliability was
also confirmed through five-year operation in GTD
center.
Careful attention was paid to dynamic
characteristics of the H-25's first three rotor
blades, and a full-scale wheel-box test was
performed. Figure 5 shows a full-scale wheel-box
test facility and Campbell diagram of the first three
rotor blades acquired using telemetry systems. It is
clear that none of the blades have resonances in
operating speed.
For the materials of the H-25 compressor blades,
12Cr-Nb stainless steel has been applied to the VIGV
and the 1st through 5th stage rotor blades. The 12Cr
stainless steel was applied for all stator blades and
the 7th through 17th rotor blades. The 1st through
8th stage rotor and stator blades are coated with
NiCd to enhance corrosion resistance.
^ 6
0
(a) Full-scale test rotor
Fig. 5 Compressor Rotor Wheel Box Test
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7^
Fig. 4 Compressor and Turbine
Combustor
A dual-fuel system for gas and oil fuel is
available for the H-25 combustor, to meet the
To permit operation at a high firing
temperature, effective cooling constructions have
been adopted for each part of the combustor. Figure
6 shows a sectional view of the combustor.
Compressor discharge air then flows into the space
between the flow sleeve and the transition piece,
cooling the surface of the transition piece.
Additional film cooling is provided especially for
hot sections of the transition piece. For the
combustion liner, slot cooling ( a kind of film
cooling) is used in combination with convection
cooling enforced by the external flow sleeve.
Figure 7 shows a photograph of the combustion
liner. This compact combustion liner has about a 30
percent volume in comparison with conventional liners
which operate at a firing temperature of under
1000°C. The aim is to reduce the cooled surface area
and the cooling flow rate, while maintaining
combustion heat loads at the same level as
conventional combustion liners.
800
N
600
3R
VR
0
v
1R
400
200
0
20 40 60 so 100 120 140
Rotor Speed (rps)
(b) Campbell diagram

Combustion liner Transition piece
Slot cooling &
convection( Convection cooling
cooling & film cooling
(
a\ Flow sleeve
Compressor discharge air
Fig. 6 Sectional View
of Combustor Combustion Liner
The material of the combustion liner and
transition piece is Ni-base superalloy, and the inner
surface of the transition piece is coated with a
ceramic thermal barrier coating. For NOx control,
steam is injected through a nozzle attached at the
combustion case cover.
During the component development stage, the
combustor was tested under actual operating
conditions of flow rate, pressure, firing temperature
and so on at a full-scale combustor test facility in
Hitachi's GTD center. An optimization of combustion
and dilution air is accomplished through this test in
combination with single-type fuel nozzle. Combustion
characteristics, reliability such as metal
temperature and dynamic behavior, and the effect of
steam injection were also confirmed.
Turbine
The 525 turbine is a low-reaction three-stage
design which brings low heat loads to rotor buckets.
The first-stage bucket is free-standing construction
and the second and third-stage buckets are
continuously connected with Z tip shrouds.
Cooling air
1
Film cooling
; Cooling air
Film cooling
Fig. 8 Turbine First Stage Nozzle
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The first-stage nozzle is single-vane design
with minimized thermal stresses, and second and
third-stage nozzles are two-vane segment design.
The first stage buckets and nozzles, which
operate in especially high gas temperature
conditions, are provided with advanced cooling
technologies (21.
Figure 8 shows an external view of the first
stage turbine nozzle and its internal cooling
configuration as well. The cooling system combines
impingement cooling, film cooling, and pin-fin
cooling. The interior is divided into two chambers
containing perforated inserts. Cooling air flows
into the inserts from the exterior, and jets out
through the small holes onto the nozzle's inner
surface, thereby achieving effective impingement
cooling. After cooling the inner surface, part of
the air blows out to the gas passage through film
cooling holes in the nozzle, forming a cooling air
film on the exterior surface. The remaining cooling
Fig. 7
air blows out to the gas passage through a pin-fin
cooling channel at the trailing edge.
Figure 9 shows an exterior view of the first
stage turbine bucket and its internal cooling
configuration. The cooling air comes in at the
bottom of the bucket and branches into front and rear
flow paths. It flows outward in both paths, then
inward after turning 180° at the blade tip. The
paths both turn again at the root of the blade, and
then the front path leads out into the gas passage
from the tip of the blade, while the rear flow enters
the gas passage via the trailing edge of the blade.
Cooling effectiveness is increased by turbulence-
promoter fins installed on the inner surface of the
channels.
A prototype model of the first-stage turbine was
made and its performance was tested. Turbine blade
cooling efficiency and aerodynamic characteristics
were both confirmed in these tests.
A newly developed cobalt-base (Co-base)
corrosion-resistant superalloy was used for the
first-stage nozzles. This new alloy has enhanced
creep-rupture strength about 30 percent in comparison
with FSX-414 Co-base alloy. For the turbine bucket
materials, the Ni-base superalloy was used. In order
to prevent hot corrosion and oxidation, the first-
stage buckets are coated with improved Co, Ni, Cr,
Al, and Y metal coating using low pressure plasma
spray technique.
Multi-path serpentine
cooling passage
Cooling
air
Forward cooling Afterw^
passage cooling
Pin-fin cooling passage
Impingement
cooling
Cooling air
Fig. 9 Turbine First Stage Bucket
 Rotor Factory Test Results

The H-25 rotor is a fully stacked disk assembly
with 17 compressor bladed disks, 3 turbine bladed
disks and 2 spacer disks. The first-stage through
16th-stage disks are of NiCrMoV or NiCrMo steel and
stage 17th disk is of CrMoV steel. For the turbine
disks and spacers, newly developed 12CrNiM0VNb steel
was used. This new disk material has improved
creep rupture strength and embrittlement toughness at
temperatures over 400 ° C.
The rotor cooling air flows into 12 drilled-
holes and radial slots of the distance piece between
compressor and turbine rotors. The air then flows
into a chamber between first-stage and second-stage
disks through the rotor bore, and is supplied to
first-stage and second-stage buckets while it cools
turbine disks during base load operation and warms up
during start-up. The air also cools a third-stage
disk and flows out to wheel space. A full-scale
model rotor was made and tested to confirm the
characteristics of disk-cooling and warming and its
capability of supplying cooling air (Figure 10).
Pressure drops of the cooling air in the rotor
internal circuits and the flow stability was
confirmed in this test.
The first machine, connected with water-
dynamometer as a loading device, was tested under
various operating conditions.
A total of 812 instrumentation sensors were
installed on the first machine, 29 of these sensors
were instrumented for rotating components as shown in
Table II. Rotating components instrumentation,
thermocouples and strain gauges, were brought out
using the high-speed 100-channel slip ring at the
front end of the shaft.
Five desktop computers, composing a local area
network, were used to acquire, process, display and
print the data to monitor the condition of each
component and part. Tests were performed using No.2
Distillate Fuel under the conditions below :
• Loading test, from no load to full load.
I Inlet guide vane modulation test for heat
recovery cycle.
Steam injection for NOx control
During the tests, this machine experienced 146
start/stop cycles and fired runs totaling 150 hours,
and the measurements were performed so well that the
broken sensors numbered less than 1 percent.
(1) Gas Turbine Performance
The power output and thermal efficiency of the
first H25 gas turbine achieved the design goal, and
the rating at the generator terminals, including
inlet/exhaust pressure losses, was committed as shown
in Table I .

(2) Turbine Blade Metal Temperatures

Three pyrometers were used to measure the
turbine blade metal temperatures of the first and the
second stage blades, together with thermocouples
through slip ring. For the first-stage blades with
serpentine cooling passages, the metal temperature
was detected both from leading-edge and trailing-edge
sides using sighting tube with Pt-Ro mirror. Cooling
air was supplied to cool and purge the lens and
mirror (Figure 11).
Figure 12 shows the results of pyrometric
measurement and reveals that the metal temperatures
were well within the allowable temperature, while the
maximum temperature spread between individual blades
was 25 ° C.
(a) Full-scale test rotor
Table II Summary of Factory Test
Instrumentation

Thermocouples 425 points

Pressure taps to measure 231
static/dynamic pressure
Pyrometer to detect blade 3
temperatures
Strain gauges to measure 41
dynamic stresses
Acceleration probes 2
• Tip clearance probes 4
Shaft vibration and 58
displacement probes
Load cell to measure 2
thrust loads
(b) Cross section of test rotor
• Acoustic emission probes 2
to detect rubbing
Fig. 10 Testing Apparatus of Cooling Air
• Miscellaneous 44
Supply System ( Total instrumentation 812

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 Figure 13 shows the comparison between
prediction of metal temperatures and those by
thermocouples. The comparison shows good agreements
between the predictions and the measured results, Measurement
excepting the pressure-side point. O
The cause of the discrepancy on the pressure-
side point is estimated to be due to flow disturbance
w
when the blades cut the upstream nozzle wake, which
40 O
greatly affects the heat transfer rate of pressure
side of the downstream blades.
a
m
a Prediction
(3) Combustor Metal Temperatures e
w
E
Figure 14 shows the outer metal temperature
distribution of the combustor liner and transition Suction side Pressure side
piece. The data shows that the metal temperatures
were well below the design goal.
Trailing Edge Leading Edge T.E.
(4) Tip Clearance Measurement Blade surface position
Tip clearances of both compressor and turbine
blades were measured by the use of four spark type
tip clearance probes. Fig. 13 1st Stage Blade Metal Temperature
Figure 15 shows the variation of tip clearances of
second-stage compressor bladesand first-stage turbine
buckets, from start to full load.
The pinch point was found at transient and steady Allowable temp.
condition, which was strongly dependent on the U 110 I Measured region
a Q
thermal response of the rotor-casing interaction. U 0 9
After the scheduled tests were completed, the J

first machine was disassembled and carefully MS -IW

inspected. The machine and each component were in a

very good condition without the necessity of ^m o
modification. MS
a)
0 2W iW (44) MW I,WII

Distance from combustor front end

Fig. 14 Metal Temperature of Combustor

Pyrometer 1 2 3

Lens
Cooling and
— purge air ° Actuator

Mirror

(a) Installation of pyrometer (b) Sighting tube

Fig. 11 Pyrometric Measurements of Blade Temperature Purge N 2 gas

Leading-edge side

1
Trailing-edge side (a) Spark probe setup

a 1.5f k
c : Cold clearance
a I-
C 1.0j /Turbine 1st stage blade
w 1 Revolution c u Compressor 2nd s`_age blade
a
C
a C
EMS
U 0.5
E aCU
m
0-

0 0 1 2 3
0.00
Time --^
l0.00. Time after Start (hour)

Fig. 12 Pyrometric Temperature Measurements (b) Test results

of Turbine 1st Blade Fig. 15 Blade Tip Clearance Measurement

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FIELD TEST AND OPERATION APPLICATION

After the first H-25 gas turbine was completed
and delivered to the site at the Tokuyama Refinery of
Idemitsu Kosan Co., Ltd. in Japan, it was installed
in place of the MS5001 gas turbine which had been
operated for more than 100,000 hours over 13 years
[4). The existing cogeneration plant equipment,
except gas turbine, was re-utilized. Figure 16 shows
this H-25 cogeneration installation. Field tests
were carried out, and the results were quite
successful under actual site conditions. Performance
and other gas turbine characteristics were as
expected. This first unit started commercial
operation at the end of November 1988. This machine
had successfully accomplished the first one-year base
load operation. Four combustion inspections and
bore-scope inspections were carried out periodically
to confirm the condition of this first unit.
The inspection results were good with the
exception of small cracks on the fuel-nozzle swirler
tips. To correct this problem, the cooling of the
swirler tip was improved to prevent cracking.
The second machine was also installed at a
refinery plant in Japan and started successful
commercial operation as a new cogeneration plant in
August 1989. The third unit will start the operation
for cogeneration service in August 1990.
(1) Physical Arrangement
Figure 17 shows the typical setup of an H-25 gas
turbine. The H-25 is a modular design consisting of
four packages : control compartment, gas turbine
package, generator package, and generator auxiliary
compartment. These packages are transported
separately and assembled at the installation site.
It typically takes about 3.5 months for erection and
testing.
(2) Cogeneration
Figure 18 shows the typical system arrangement
and layout of a cogeneration plant. The total
thermal efficiency of the H-25 cogeneration plant is
higher than a conventional gas turbine cogeneration
plant because of its higher exhaust temperature.
(3) Replacement of MS5001 Gas Turbine
The H-25 gas turbine can be used not only for
new power plants, but also for replacement of
existing MS5001 gas turbines. In this case, fuel
consumption can be reduced by approximately 20%, and
many existing components such as the generator, inlet
and exhaust facilities, and a variety of accessory
equipment can be re-used.

Process steam

DeNOx
Desuper heater

Fuel Exhaus t

Inlet air
Waste heat boiler
Fecd water

I!-25 gas turbine Generator

(a) System arrangement

Fig.16 H-25 Cogeneration Plant,Tokuyama,Japan H-25 gas turbine

Oil tank Inlet filter

-
--- Generator

t E Fuel forwarding pump

{ - - Electrical
room
_ 36 .5 _ Waste heat boiler
Stack
I i
Inlet filter
x Inlet duct
Exhaust duct
Inlet filter

Oil tank Generator

GL

Exhaust
Package Weight (ton)
l) Control compartment to
0
2 Gas turbine package 87
0
3 Generator package 82 q ^ s ium
Generator auxiliary
13
(b) Layout

Fig. 17 Machine Arrangement Fig. 18 Typical System Arrangement and Layout

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 CONCLUSION

A new 25MW class gas turbine H-25 was developed

and the features of this gas turbine were described.
The results of the factory test and the field
test showed that the H-25 achieved the highest level
of performance among existing 25MW class of heavy-
duty gas turbines, and design goals concerning
reliability such as hot parts metal temperatures were
well satisfied.
The first unit of H-25 started commercial
operation at the end of November 1988, and has now
operated continuously over 7,100 hours for one year.
The inspection results showed good reliability of
this machine under actual operating condition.
We intend to accumulate on-site operation
records of this gas turbine while complying with
customers' various needs.

REFERENCES

(1) K. Kawaike et al., "Effect of New Blade Cooling

System with Minimized Gas Temperature Dilution
on Gas Turbine Performance," Journal of
Engineering for Gas Turbines and Power, Trans,
ASME 106, No. pp.756-764 (Oct.1984)[84-GT-89]

(2) M. Shizuya and K. Kawaike, "Experimental

Investigation of Blade Internal Cooling Methods
Using Ribs and Fins", Proceedings of the 1987
Tokyo International Gas Turbine Congress III
pp.159-166 (Oct. 1987) [87-TOKYO-IGTCD-65].

(3) Y. Kashiwabara et al., "Development of a High-

Pressure-Ratio Axial Flow Compressor for a
Medium-size Gas Turbine" Journal of
Turbomachinery, Trans. ASME 108 pp. 233-239
(Oct. 1986)[86-GT-85]

(4) R. Furukawazono et al., "A Prototype Replacement

of a 100,000 Hours Operation, 25,000 kW Gas
Turbine at Idemitsu Kosan Co., Ltd." ASME Gas
Turbine and Aeroengine Congress and Exposition
(Jun. 1989) [89-GT-26]

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