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GER-3695E
GE Power Systems
GE Aeroderivative
Gas Turbines - Design
and Operating Features
G.H. Badeer
GE IAD
GE Power Systems
Evendale, OH
GE Aeroderivative Gas Turbines - Design and Operating Features
Contents
Abstract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Selection of Aeroderivative Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
LM1600 Gas Turbine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
LM2500 Gas Turbine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
LM2500+ Gas Turbine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
LM6000 Gas Turbine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
LM6000 Sprint™ System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
STIG™ Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Design and Operation of GE Aeroderivative Gas Turbines . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Design Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Fuels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Ratings Flexibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Performance Deterioration and Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Maintenance Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Advances in Aircraft Engine Technology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Figure 1. GE aeroderivative product line: generator drive gas turbine performance characteristics
Figure 2. GE aeroderivative product line: mechanical drive gas turbine performance characteristics
line of aircraft engines, GE considers the fol- cost as low as possible, the aircraft engine cho-
lowing factors: sen as the basis for this line must be convertible
■ Market forecast for marine and from aircraft to marine and industrial usage:
industrial engines ■ With very few changes to its original
■ Projected performance and price design
competitiveness of the new line of ■ Using parts which are mass-produced
aeroderivative engines for the aircraft application.
■ Degree of difficulty involved in Figure 4 shows the operating hours accrued for
converting the aircraft engines design each of the GE parent engines in flight applica-
into the new, aeroderivative tions and their derivative engines in industrial
configuration. and marine service. For example, the LM2500
The last point is extremely important. In order and its parent aircraft engine have over 63 mil-
to keep a new aeroderivative product’s overall lion hours of operating experience and have
AIRCRAFT AERODERIVATIVE
QUANTITY OPERATING HOURS QUANTITY OPERATING HOURS
LM1600
(F404) 3400 7,000,000 146 3,500,000
LM2500
(TF39/CF6-6) 1130 32,300,000 1767 31,200,000
LM6000
(CF6-80C2) 2806 58,700,000 300 3,200,000
Data as of February, 2000
Fuel
LPC HPC H L
P P PT
T T
Load Load
Variable Stators
Variable Bleed
Variable IGV
Core Engine
Aeroderivative turbines are available with two thermal cycling and can operate at constant
types of annular combustors. Similar to those speed for generator drive applications, and over
used in flight applications, the single annular a cubic load curve for mechanical drive appli-
combustor features a through-flow, venturi cations. The LM6000 power turbine drives both
swirler to provide a uniform exit temperature the LPC and the load device. This feature facil-
profile and distribution. This combustor config- itates driving the load from either the front or
uration features individually replaceable fuel aft end of the gas turbine shaft.
nozzles, a full-machined-ring liner for long life,
and an yttrium-stabilized zirconium thermal All of the models have an engine-mounted,
barrier coating to improve hot corrosive resist- accessory drive gearbox for starting the unit
ance. In 1995, a dry, low emissions (DLE) com- and supplying power for critical accessories.
bustor was introduced to achieve low emissions Power is extracted through a radial drive shaft
without the use of fuel diluents, such as water or at the forward end of the compressor. Drive
steam. pads are provided for accessories, including the
lube and scavenge pump, the starter, the vari-
The LM1600, LM2000, LM2500, and LM2500+
able-geometry control, and the liquid fuel
all include an aerodynamically coupled, high-
pump.
efficiency power turbine. All power turbines are
fully tip-shrouded. The LM1600 PT and
LM2500+ High Speed Power Turbine (HSPT) LM1600 Gas Turbine
feature a cantilever-supported rotor. The power The LM1600 gas turbine consists of a dual-rotor
turbine is attached to the gas generator by a gas generator and an aerodynamically coupled
transition duct that also serves to direct the power turbine. The LM1600 is shown in Figure
exhaust gases from the gas generator into the 6, and consists of a three-stage, low-pressure
stage one turbine nozzles. Output power is compressor; a seven-stage, variable-geometry,
transmitted to the load by means of a coupling high-pressure compressor; an annular combus-
adapter on the aft end of the power turbine tor with 18 individually replaceable fuel nozzles;
rotor shaft. Turbine rotation is clockwise when a single-stage, high-pressure turbine; and a sin-
viewed from the coupling adapter looking for- gle-stage, low-pressure turbine. The gas genera-
ward. Power turbines are designed for frequent tor operates at a compression ratio of 22:1.
The LM1600 incorporates variable-geometry in high-pressure turbine, the nozzles and blades
its LPC inlet guide vanes and HPC stator vanes. are air-cooled. For industrial applications, the
Four electronically operated, variable-geometry nozzles are coated with CODEP and the blades
bleed valves match the discharge airflow are coated with platinum-aluminide to improve
between the LPC and HPC. In industrial appli- resistance to erosion, corrosion and oxidation.
cations, the nozzles and blades of both the HPT
The six-stage power turbine operates at a nomi-
and LPT are air-cooled and coated with
nal speed of 3,600 rpm, making it ideal for 60
“CODEP,” a nickel-aluminide-based coating, to
Hz generating service. Alternatively, it can be
improve resistance to oxidation, erosion, and
used in 50 Hz service without the need to add a
corrosion. For marine applications, HPT noz-
speed reduction gear. The LM2500 can also
zles are coated with a thermal barrier coating,
operate efficiently over a cubic load curve for
LPT nozzles are coated with CODEP and the
mechanical drive applications.
blades of both the HPT and LPT are coated
with PBC22. The two-stage power turbine The LM2500 gas turbine is also offered at an
operates at a constant speed of 7,000 rpm over 18MW ISO rating as an integrated packaged
the engine operating range for generator drive product called the LM2000 with an extended
applications, and over a cubic load curve for hot-section life for the gas turbine.
mechanical drive applications.
LM2500+ Gas Turbine
LM2500 Gas Turbine The first LM2500+, a design based on the very
The LM2500 gas turbine consists of a single- successful heritage of the LM2500 gas turbine,
rotor gas turbine and an aerodynamically cou- rolled off the production line in December
pled power turbine. The LM2500 (Figure 7) 1996. The LM2500+ was originally rated at 27.6
consists of a six-stage, axial-flow design com- MW, for a nominal 37.5% thermal efficiency at
pressor, an annular combustor with 30 individu- ISO, no losses and 60 Hz. Since that time, its rat-
ally replaceable fuel nozzles, a two-stage, high- ing has continually increased to reach its cur-
pressure turbine, and a six-stage, high-efficiency rent level of 31.3 MW and 41% thermal effi-
power turbine. The gas generator operates at a ciency. An isometric view of the LM2500+ gas
compression ratio of 18:1. turbine, including the single annular combus-
The inlet guide vanes and the first six-stages of tor (SAC), is shown in Figure 8.
stator vanes are variable. In both stages of the The LM2500+ has a revised and upgraded com-
pressor section with an added zero stage for ■ Casing isolation from flow path gases
increased flow and pressure ratio, and revised by use of liners stages 1-3.
materials and design in the HP and power tur- The LM2500+ two-stage HSPT has a design
bines. The gas generator operates at a compres- speed of 6100 rpm, with an operating speed
sion ratio of 22:1. The inlet end of the LM2500+ range of 3050 to 6400 rpm. It is sold for
design is approximately 13 inches/330 mm mechanical drive and other applications where
longer than the current LM2500, allowing for continuous shaft output speeds of 6400 rpm are
retrofit with only slight inlet plenum modifica- desirable. When the HSPT is used at 6,100 rpm
tions. In addition to the hanging support found to drive an electric generator through a speed
on the LM2500, the front frame of the reduction gear, it provides one of the best
LM2500+ has been modified to provide addi- options available for power generation applica-
tional mount link pads on the side. This allows tions at 50 Hz.
engine mounting on supports in the base skid.
Both the six-stage and two-stage power turbine
The LM2500+ is offered with two types of power options can be operated over a cubic load curve
turbines: a six-stage, low speed model, with a for mechanical drive applications.
nominal speed of 3600 rpm; or a two-stage high In 1998, a version of LM2500+ was introduced
speed power turbine (HSPT). to commercial marine application. The only dif-
The LM2500+ six-stage power turbine displays ferences between the marine and industrial ver-
several subtle improvements over the L2500 sions to address the harsher environment are as
model from which it was derived: follows:
two-stage, air-cooled HPT; and a five-stage LPT. ator only, and adds a unique power turbine. By
The overall compression ratio is 29:1. The maintaining high commonality, the LM6000
LM6000 does not have an aerodynamically cou- offers reduced parts cost and demonstrated reli-
pled power turbine. ability.
The LM6000 is a dual-rotor, “direct drive” gas The status of the LM6000 program, as of
turbine, derived from the CF6-80C2, high- February 2000, includes:
bypass, turbofan aircraft engine. The LM6000
takes advantage of its parent aircraft engine’s ■ 300 units produced since introduction
low-pressure rotor operating speed of approxi- in 1991
mately 3,600 rpm. The low-pressure rotor is the ■ 208 units in commercial operation
driven-equipment driver, providing for direct ■ First DLE combustor in commercial
coupling of the gas turbine low-pressure system operation producing less than 25 ppm
to the load, as well as the option of either cold NOx - 1995
end or hot end drive arrangements.
■ High time engine =50,829 hours
The LM6000 maintains an extraordinarily high
■ 12 month rolling average engine
degree of commonality with its parent aircraft
availability = 96.8%
engine, as illustrated in Figure 10. This is unlike
the conventional aeroderivative approach ■ Engine reliability = 98.8%
which maintains commonality in the gas gener- ■ Exceeded 3.1 million operating hours
Traditional Approach
Common Unique
HP HP Generator or Compressor
Compressor Turbine
LP LP
Compressor Turbine Power
Turbine
Common
LM6000 Approach
■ Variable speed mechanical drive atomized water injection at both LPC and HPC
capability – 1998 inlet plenums. This is accomplished by using a
■ Dual fuel DLE in commercial high-pressure compressor, eighth-stage bleed
operation – 1998 air to feed two air manifolds, water-injection
manifolds, and sets of spray nozzles, where the
■ LM6000 PC Sprint™ System in
water droplets are sufficiently atomized before
commercial operation - 1998
injection at both LPC and HPC inlet plenums.
In mid-1995, GE committed to a major product Figure 11 displays a cross-section of the LM6000
improvement initiative for the LM6000. New Sprint™ System. Figure 12 provides the Sprint™
models designated as LM6000 PC/PD were first Gas Turbine expected performance enhance-
produced in 1997, and included a significant ment, relative to the LM6000-PC.
increase in power output (to more than 43 Since June 1998, when the first two
MW) and thermal efficiency (to more than Sprint™units began commercial operation, ten
42%); dual fuel DLE; and other improvements other installations have gone into service. As of
to further enhance product reliability. February 2000, LM6000 Sprint™ Gas Turbine
(Figure 13) operating experience exceeds
LM6000 Sprint™ System
20,000 hours. Sprint™ System conversion kits
Unlike most gas turbines, the LM6000 is prima- for LM6000 PC models are now available for
rily controlled by the compressor discharge those considering a potential retrofit.
temperature (T3) in lieu of the turbine inlet
temperature. Some of the compressor dis- STIG™ Systems
charge air is then used to cool HPT compo- STIG™ (Steam Injected Gas Turbine) systems
nents. SPRINT™ (Spray Inter-cooled Turbine) operate with an enhanced cycle, which uses
reduces compressor discharge temperature, large volumes of steam to increase power and
thereby allowing advancement of the throttle to improve efficiency. See Figure 14 for STIG™ sys-
significantly enhance power by 12% at ISO, and tem performance enhancements at ISO base
greater than 30% at 90°F (32°C) ambient tem- load conditions.
peratures. In the STIG™ cycle, steam is typically produced
The LM6000 Sprint™ System is composed of in a heat recovery steam generator (HRSG) and
Water
Air Metering
Manifold Valve Air
Orifice Manifold
23 Spray 24 Spray
Nozzles Nozzles
Water Manifold
8th Stage
Bleed Air Piping
55000
50000
12%
Shaft Power kW
TM
45000 SPRINT
40000
30%
35000
Base LM6000-PC
30000
Sea level, 60% Rel Hum, 5" Inlet/10" Exhaust losses
Natural Gas with Water Injection to 25 ppm
25000
40 50 60 70 80 90 100
Engine Inlet Temperature deg F
Standard Base Load, Sea Level, 60% RH, - Natural Gas - 60 Hertz -
4 in. (102mm) Inlet/10 in. (254mm) Exhaust Loss - Average Engine at the Generator Terminals*
Model Dry Rating (MWe) %Thermal Efficiency (LHV) STIG Rating (MWe) %Thermal Efficiency (LHV)
LM1600 13.3 35 16 37
LM2000 18 35 23.2 39
LM2500 22.2 35 27.4 39
Figure 14. STIG™ system performance enhancement – generator drive gas turbine performance
is then injected into the gas turbine. The installation includes a steam-injected gas tur-
STIG™ system offers a fully flexible operating bine, coupled with an HRSG which can be sup-
cycle, since the amount of steam injected can plementally fired. The control system regulates
vary with load requirements and steam avail- the amount of steam sent to process and, typi-
ability. Also, steam can be injected with the gas cally, the excess steam is available for injection.
turbine operating from 50% power to full load. Figure 16 shows the steam injection capability
A typical STIG™ cycle is shown in Figure 15. The for the various models.
Exhaust
To process
H 2O
HRSG
Steam
Fuel
Gas turbine
~
Air
Standard Base Load, Sea Level, 60% RH, - Natural Gas - 60 Hertz -
4 in. (102mm) Inlet/10 in. (254mm) Exhaust Loss - 25 PPM NOx
Steam Flows -lb/hr (kg/hr)
Model Rating (MWe)* %Thermal Efficiency* Fuel Nozzle Compressor Discharge
LM1600 16 37 11540 (5235) 9840 (4463)
LM2000 23.2 39 14558 (6604) 15442 (7005)
LM2500 27.4 39 18300 (8301) 31700 (14379)
LM2500+ 32.5 40 23700 (10750)
LM6000 42.3 41.1 28720 (13027)
* Average Engine at generator terminals
(2.5% on LM1600 Gen, 2.0% on all others Gen, 1.5% GB included)
Figure 16. STIG™ steam flow capability – generator drive gas turbine performance
HP Steam to
combustor for
NOx abatement
HP Steam for
power augmentation
Figure 19. Minimum NOx emission guarantee levels – wet and dry emissions control options
Combustion Liner
Heat Shield
Premixer
In order to achieve low emissions throughout opment on the Dual Fuel DLE front.
the operating range, fuel is staged through the Completely dry operation has been achieved on
use of multiple annuli. The LM1600 uses a dou- gas and distillate fuels on two LM6000 engines
ble annular configuration, while all other mod- in the United Kingdom. Operating on liquid
els use a triple annular construction. fuel, NOx and CO emission levels have been less
than 125 ppm and 25 ppm, respectively. GE
Factory testing of components and engine
continues to do research on reducing liquid
assembly on an LM6000 gas turbine was com-
fuel to NOx levels below 65 ppm , with the goal
pleted in 1994. These tests demonstrated less
of achieving this by the end of the year 2000. By
than 15 ppm NOx, 10 ppm CO and 2 ppm UHC
early 2001, GE plans to release a Dual Fuel DLE
at a firing temperature of 2350°F/1288°C at
system on the LM2000, LM2500 and LM2500+
rated power of 41 MW.
gas turbines.
The Ghent power station in Belgium became
the first commercial operator to use the Design and Operation of GE
LM6000 fitted with the new DLE combustor sys-
Aeroderivative Gas Turbines
tem. A milestone was reached in January 1995
when the station achieved full power at 43 MW Design Features
with low emissions of 16 ppm NOx, 6 ppm CO GE Aeroderivative gas turbines combine high
and 1 ppm UHC. As of today, the high time temperature technology and high pressure
LM6000 engine has accumulated over 34,000 ratios with the latest metallurgy to achieve sim-
hours. ple-cycle efficiencies above 40%, the highest
By the end of 1999, there were 3 LM1600, 58 available in the industry.
LM2500, 27 LM2500+, and 30 LM6000 gas tur- It is essential to GE’s aeroderivative design phi-
bines equipped with the DLE combustion sys- losophy that an industrial or marine aeroderiv-
tem in service worldwide. ative gas turbine retain the highest possible
Today, GE continues its DLE technology devel- degree of commonality with the flight engine
on which the aeroderivative is based. This with other bearing designs. Roller bearings
results in a unique and highly successful have proven to be extremely rugged and have
approach to on-site preventive and corrective demonstrated excellent life in industrial serv-
maintenance, including partial disassembly of ice. Although bearings generally provide reli-
the engine and replacement of components able service for over 100,000 hours, in practice,
such as blades, vanes and bearings. On-site it is advisable to replace them when they are
component removal and replacement can be exposed during major repairs, or, at an estimat-
accomplished in less than 100 manhours. ed 50,000 hours for gas generators and 100,000
Complete gas generators and gas turbines can hours for power turbines.
be made available within 72 hours (guaran- The high-efficiency aeroderivative is an excel-
teed), with the complete unit replaced and lent choice for simple-cycle power generation
back on-line within 48 hours. The hot-section and cyclic applications such as peaking power,
repair interval for the aeroderivative meets the which parallels aircraft engine use. With start
industrial demand of 25,000 hours on natural times in the one-minute range, the aeroderiva-
gas. The LM engines have been adapted to tive is ideal for emergency power applications of
meet the important industrial standards of any sort.
ASME, API, NEC, ISO9001, etc., consistent with
With its inherently low rotor inertias, and the
their aircraft engine parentage.
variety of pneumatic and hydraulic starting
Other advantages related to the evolution from options available, the GE Aeroderivative engine
the flight application are the technical require- has excellent “black start capability,” meaning
ments of reduced size and low weight. The the ability to bring a “cold iron” machine on-
aeroderivatives’ rotor speeds (between 3,000 line when a source of outside electrical power is
and 16,500 rpm) and casing pressure (20 to 30 unavailable. An additional benefit of having low
atmospheres) may appear high when compared rotor inertias is that starting torques and power
with other types of gas turbines. However, the requirements are relatively low, which in turn
high strength materials specified for the aircraft reduces the size and installed cost of either the
engine are capable of handling these pressures pneumatic media storage system or the diesel
and rotor speeds with significant stress margins. or gasoline engine driven hydraulic systems. For
For example, cast Inconel 718, commonly used example, the LM2500 starting torque is less
for aircraft engine casing material, has a yield than 750 ft-lbs (1,017 N-m), and its air con-
strength of 104 ksi (717 kN/m2) at sumption during a typical start cycle is between
1200°F/649°C, while cast iron commonly used 2,000 and 2,600 SCFM (56,600 and 73,600
in other types of gas turbine casings has a yield l/min).
strength of 40 ksi at 650°F (276 kN/m2 at
Fuels
343°C).
Natural gas and distillate oil are the fuels most
The aeroderivative design, with its low support- frequently utilized by aeroderivatives. These
ed-weight rotors – for example, the LM2500 HP engines can burn gaseous fuels with heating val-
rotor weighs 971 lbs/441 kg – incorporates ues as low as 6,500 Btu/lb (15,120 kJ/kg).
roller bearings throughout. These do not Recently, an LM6000 with a single, annular
require the large lube oil reservoirs, coolers and combustor was modified to operate on medium
pumps or the pre-and post-lube cycle associated Btu (8,000-8,600 Btu/lb ~ 18,600-20,000 kJ/kg)
fuel. It demonstrated that it could operate with is an exception; at its base rating the hot-section
lower NOx emissions without requiring flame- repair interval is approximately 50,000 hours.
quenching diluents such as water or steam. Aeroderivatives utilize the same basic hardware
As part of GE’s Research and Development as aircraft engines, which are designed to oper-
Program, an LM2500 combustor, modified to ate reliably at firing temperatures much higher
utilize low heating value biomass fuel, has been than the corresponding aeroderivative base rat-
operated in a full annular configuration at ing temperatures. By taking advantage of the
atmospheric pressure. A sector of the annular extensively air cooled hot-gas-path components
combustor design was then tested at gas turbine typically found in aircraft engines, aeroderiva-
operating pressures. Ignition, operability, gas tive models can operate at higher temperatures
temperature radial profiles, temperature varia- and power levels than their base rating.
tions and fuel switching were in acceptable The LM2500 will be used as an example, with
ranges when operated on simulated biomass the other LM products having similar charac-
fuel. Low NOx is a by-product since low heating teristics. Figure 21 illustrates the full capability of
value fuel is essentially the same as operating in the LM2500 as a function of ambient tempera-
a lean premix mode like the DLE combustor. ture. In the ambient temperature region above
Operating Conditions 55°F/13°C, the LM2500’s maximum capability
is limited by the maximum allowable tempera-
The climatological and environmental operat-
ture at the power turbine inlet. Figure 21 also
ing conditions for aeroderivatives are the same
shows the availability of additional power above
as for other types of gas turbines. Inlet filtration
the ISO base rating of the unit.
is necessary for gas turbines located in areas
where sand, salt and other airborne contami- In order to achieve this increased power, opera-
nants may be present. tion at increased cycle temperature is necessary.
As with any gas turbine, the hot-gas-path section
At the extreme ends of the ambient tempera-
repair interval (HSRI) of the LM2500 is related
ture spectrum, the aeroderivative exhibits a less
to the cycle temperature. Figure 22 presents the
attractive lapse rate (power reduction at off-
relationship between output power, power tur-
ambient temperatures) than other types of gas
turbines. However, the LM aeroderivative does
have a “constant power” performance option
which can be applied in areas where the
extremes are encountered for extended periods
of time.
Ratings Flexibility
All turbines, including aeroderivatives, have
“base ratings”. In the case of GE’s aeroderiva-
tives, when natural gas is used as the fuel and
the engine is operated at the base power tur-
bine inlet temperature control setting, its base
rating corresponds to a hot-section repair inter-
val of approximately 25,000 hours. The LM2000 Figure 21. LM2500 maximum power capability
section repair interval of 25,000 hours, poten- severity of the local environment and opera-
tial power at low ambient temperatures has tional profile of the site determine the frequen-
been traded for more potential power at higher cy of washing.
ambient temperatures. Again, for an applica- Studies of representative engines in various
tion where the required power is independent applications show a predictable, nonrecover-
of the ambient temperature, a constant power able performance loss over long-term use.
rating results in trading off the higher power at Deterioration experience is summarized in
low ambient temperatures for extended con- Figure 25 for power and heat rate for an LM
stant power at higher ambient temperatures. aeroderivative gas turbine operating on natural
gas fuel.
Figure 24. LM2500 constant PT inlet temperature Figure 25. LM2500 field trends – power and heat
and constant power operation rate deterioration
repairs are performed at the same time. and combustion module replacement
General overhauls at about 50,000-hour inter- is 72 hours. This exchange allows the
vals entail more comprehensive component gas turbine to operate for an
restorations throughout the engine, and may additional 25,000 hours.
result in nearly 100% restoration of the non- ■ Compactness. The GE AeroDerivative
recoverable performance. engines have inherited modest
When using liquid fuel, which is more corrosive dimensions and lightweight
than natural gas, a similar but more rapid pat- construction that generally allows for
tern of deterioration occurs, resulting in on-site replacement in less than 48
approximately the same 3% to 5% level at the hours.
typical 12,500-hour liquid-fuel HPT repair inter- ■ Monitoring and Diagnostics Services
val. are made available by establishing
direct phone connections from the
Maintenance Features control system at the customers' sites
In an operator’s life cycle cost equation, the to computers in GE's LM monitoring
most important factors are engine availability center. These services link the
and maintenance cost. To enhance these con- expertise at the factory with the
siderations in regard to its aeroderivative operations in the field to improve
engines, GE has invested considerable effort in availability, reliability, operating
developing features to optimize the result of performance, and maintenance
this equation. GE’s aeroderivatives’ unique effectiveness. Monitoring of key
designs allow for maintenance plans with the parameters by factory experts allows
following features: early diagnosis of equipment problems
■ Borescope inspection capability. This and avoidance of expensive secondary
feature allows on-station, internal damage. The ability for service
inspections to determine the engineers to view real-time operations
condition of internal components, in many cases results in accelerated
thereby increasing the interval troubleshooting without requiring a
between scheduled, periodic removals site visit (Figure 26).
of engines. When the condition of the
internal components of the affected
module has deteriorated to such an
extent that continued operation is not
practical, the maintenance program
calls for exchange of that module.
■ Modular design. Using their flight
heritage to maximum advantage,
aeroderivative engines are designed to
allow for on-site, rapid exchange of
major modules within the gas turbine.
Figure 26. Monitoring and Diagnostic services: GE
The elapsed time for a typical HPT
engineer remotely monitoring a unit
•
– Magnetic Bearings
Metals
• Technology Aids GE’s continued investment in R&D aircraft
– Six Sigma Processes
– High temperature Alloys
–
• N5. N6, R88DT, MX4
Intermetallic Alloys
–
–
Remote Monitoring & Diagnostics
Concurrent Engineering/Manufacturing engine technology enables the LM series of gas
– Design Engineering Workstations
• NiAl, TiAl, Orthorhombic Ti
– Structural Ti Castings
–
–
Computational Fluid Dynamics
Process turbines to maintain their leadership position
• Non-metals – Modeling
– Polymeric Composites
• PMR 15 Case
–
–
Stereolithography Apparatus
Virtual Reality in technology, performance, operational flexi-
• Composite Fan Blade – Advanced Instrumentation
– High Temperature Polymerics (700oF/371oC)
– Thermal Barrier Coatings
– New Product Introduction Methods
bility, and value to the customer. Offered in
Figure 27. New processes and technologies power output from 13 to 47 MW, and having the
ability to operate with a variety of fuels and applications, from power generation to
emission control technologies, GE’s aeroderiva- mechanical drive, for the exploration, produc-
tive gas turbines have gained the widest accept- tion and transmission of oil and gas, as well as
ance in the industry, with total operating expe- marine propulsion systems including transport,
rience in excess of 41million hours. These tur- ferryboat, and cruise ship installations.
bines have been selected for a multitude of
List of Figures
Figure 1. GE aeroderivative product line – generator drive gas turbine performance
Figure 2. GE aeroderivative product line – mechanical drive gas turbine performance
Figure 3. Available GE aeroderivative product line equipment arrangements
Figure 4. Aircraft and aeroderivative engine operating experience as of February 2000
Figure 5. Gas turbine terminology and arrangement
Figure 6. LM1600 gas turbine
Figure 7. LM2500 gas turbine
Figure 8. LM2500+ gas turbine
Figure 9. LM6000 gas turbine
Figure 10. LM6000 concept
Figure 11. LM6000 Sprint™ flow cross-section
Figure 12. LM6000 Sprint™ performance enhancement
Figure 13. LM6000 Sprint™ gas turbine
Figure 14. STIG™ System performance enhancement- generator drive gas turbine performance
Figure 15. Typical STIG™ cycle
Figure 16. STIG™ steam flow capability generator drive gas turbine performance
Figure 17 LM2500 STIG™ steam injection ports
Figure 18. GE aeroderivative gas turbine unabated NOx emissions
Figure 19. Minimum NOx emission guarantee levels - wet and dry emissions control options
Figure 20. DLE combustor
Figure 21. LM2500 maximum power capability
Figure 22. Effect of increased power rating on LM2500 hot-section repair interval
Figure 23. LM2500 constant power rating
Figure 24. LM2500 constant PT inlet temperature and constant power operation
Figure 25. LM2500 field trends - power and heat rate deterioration
Figure 26. Monitoring and Diagnostic Services: GE engineer remotely monitoring a unit.
Figure 27. New processes and technologies
Figure 28. GE90 high-bypass fan engine on Boeing 777