Journal of Power and Energy Systems

Vol. 5, No. 2, 2011

Evolution and Future Trend of Large Frame Gas Turbine for Power Generation*
Atsushi MAEKAWA**
**Mitsubishi Heavy Industries, LTD 35 Shinanomachi, Shinjuku, Tokyo, Japan E-mail:atsushi_maekawa@mhi.co.jp

Abstract Mitsubishi Heavy Industries, Ltd. (MHI) developed a 1100C class D series gas turbine in the 1980s and constructed the worlds first successful large-scale combined cycle power plant. Since then, MHI has developed the F and G series gas turbines with higher turbine inlet temperature and has delivered these units worldwide accumulating successful commercial operations. These gas turbines are constantly improved, adding to their successful operation. MHI is currently participating in a Japanese National Project to promote the development of component technology for the next generation 1700C class gas turbine. The thermal efficiency will be improved significantly with this new technology by raising the turbine inlet temperature and the pressure ratio. MHI recently developed a 1600C class J series gas turbine utilizing some of the technologies developed in the National Project. This paper discusses the history and the evolution of MHI large frame gas turbine for power generation and the activities currently in progress for an environmentally friendly technology in the future. Key words: Combined Cycle, 1700C Class Gas Turbine, 1600C Class GAS Turbine, J Series Gas Turbine, G Series Gas Turbine

1. Background
The Kyoto Protocol came into effect in February 2005, targeting prevention of global warming by developing environmentally friendly energy sources and energy conservation. MHI contribute to pursue the balanced concept of 3E (Energy security, Environmental protection, Economical growth). The simultaneous achievement of 3E requires (1) the reduction of final energy use (energy conservation and improved efficiency on the user side), (2) the improvement of energy conversion efficiency (reduction of primary energy use), (3) the promotion of low-carbon energy use (nuclear power and renewable energy), and (4) the recovery, storage, and use of generated CO2. Our company possesses a wide variety of products and technologies that help curbing the negative effects of economic growth that lead to increased energy consumption and CO2 emissions. High conversion efficiency is aggressively targeted to reduce dependency on fossil fuels and to reduce waste materials generated in energy conversion, while maximizing the use of renewable energy such as nuclear, solar, wind, and geothermal. Steps have been taken to further improve the already unsurpassed thermal power generation efficiency of gas turbine combined cycle (GTCC) technology. MHI has pursued increased efficiency from the introduction of the M701D gas turbine (Turbine inlet Temperature (TIT) 1150C) with the first Dry Low NOx (DLN) combustor. This was followed by the development of the F series gas turbine (TIT 1350C) and the G

*Received 18 Oct., 2010 (No. 10-231-6) [DOI: 10.1299/jpes.5.161]

Copyright 2011 by JSME

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series gas turbine (TIT 1500C) in 1997, with the first steam cooled combustor liner. The H series, which expanded steam cooling technologies from the combustor liners to the row 1 and 2 blade & vanes, was tested in 1999 and 2001 with success. Currently, MHI is engaged in a Japanese National Project that targets the development of a 1700C TIT gas turbine. Six component technologies are addressed in this project. This paper describes: (1) MHI G series gas turbine design features and upgrades experience. (1500C TIT) (2) The Japanese National Project 1700C gas turbine component technology development status. (3) MHI J series gas turbine design features. (1600C TIT)

2. History of Gas Turbine Development

Figure 1 shows MHI gas turbine development history. MHI developed the 1150C class large capacity gas turbine, M701D in 1981, and subsequently verified its high plant total thermal efficiency, high reliability and low pollution at Tohoku Electric Power CO. Inc., Higashi Niigata Thermal Power Plant #3 Power Train. In 1985, MHI started the development of the 1350C class F series gas turbine (M501F/M701F). Its actual loading shop test was conducted on the initial unit in 1989. This was followed by the development of the 1500C class G series gas turbine (M501G/M701G) in 1993. A trial operation of the M501G gas turbine for 60Hz market started in February 1997 at the Takasago in-house verification plant (T-Point) where it continued long term operation to validate its availability and reliability characteristics. The M701G gas turbine for 50Hz market was started a trial operation at Tohoku Electric Power Co. Inc., Higashi Niigata Thermal Power Plant #4 Power Train on October 15, 1998, and was put into commercial operation in July 1999.
1600
Scale design Up rating design

High efficiency Combined cycle

M501J

M701J

1500

M501G Cogeneration

Turbine Inlet Temperature

M501H

M701G Application of G technology

1400

M501F3 M501F

M701F3 M701F

1300

MF-111

MF-221 M501DA M701DA

1200 MF-61 1100 M151 1000 5 10 20 40 80 160 320 M501D M251 M501B M701B M701D

Power Output (MW)

Figure 1

Trend of increasing turbine inlet temperature

MHI is currently participating the actively in a Japanese National Project that targets 62 to 65% combined cycle efficiency through the development of a 1700C class gas turbine. Part of the component technology developed for the National Project is applicable to a new 1600C class (J series) gas turbine. The target combined cycle efficiency of J is 60% or higher and the 1on1 combined cycle output will reach 460MW for the 60Hz engine and 670MW for the 50Hz counterpart, as shown in Figure 2.

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GTCC Efficiency Efficiency GTCC Efficiency

1700Cclass J Series
Power Output (MW)

Power Output
700 GTCC Configuration : 1 GT+1 ST 600 500 400 300 60Hz 50Hz

670

60 GTCC Efficiency (LHV %)

G Series F Series

GTCC G/T

465 399
312 267

498

460 460

55

334

280
200

320

213 167
144

185

50

D Series

100 114

1200 1300 1400 1500 1600 1700 Turbine Inlet Temperature ()

D Series

F Series

G Series

J Series

Figure 2

Mitsubishi gas turbine performance (Efficiency)

3. G Engine Evolution and Experience

3.1 G series Design Features The basic structural design of the G series gas turbine followed the previous Mitsubishi large industrial gas turbines, e.g. cold-end drive, two-bearing support, cannular type combustor and 4 stage turbine. The key design features of the M501G gas turbine are summarized in Figure 3.

Figure 3

M501G Design Features

The TIT can be increased to improve Combined Cycle (C/C) efficiency; however, this also induces increased NOx emissions. In an air cooled combustor, cooling air flows into the combustor inducing a reduction of combustion gas temperature. The flame temperature reduction can be as high as 100C for units that have 1500 or 1600C turbine inlet temperature. By applying the closed loop steam cooling from the bottoming cycle, the turbine inlet temperature is not diluted and therefore it remains high. NOx is directly related with the flame temperature while the C/C performance is improved by TIT, therefore the steam

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cooled combustor provides higher cycle efficiency with the same NOx emission. (Figure 4)
Air Cooled Comb (F technology)
Air (Supply) Flame Temp Steam (Return)

Steam Cooled Comb (G Technology)

Steam (Supply) Flame Temp

Hot gas path 1400 Turb Inlet Temp

Hot gas path Turb Inlet Temp

Figure 4

Air Cooled Combustor vs. Steam Cooled Combustor

3.2 G series gas turbine verification and operating experience The facility at T-point consists of full scale power plant with a 1:1 configuration. Figure 5 shows a Air Cooled bird-view picture of T-point. While Condenser HRSG the power plant serves as an Steam Turbine important test verification plant, it also dispatches electric power to a Control Center Gas local utility under contractual Turbine expectations on high reliability and availability. The supply of electricity Fuel Gas Compressor to the utility is primarily for augmenting its peak demand during Figure 5 Bird view of T-Point summer.
Operating Experience(Jun.28'97 July.31'10)
*

Typical Operating Pattern

DSS operation mode

Continuous operation 342 Days ** WSS operation 158 Days

Total Power Supply Total Operating Hours No.of Starts Availability *** Environment Parameters (NOx,Noise etc.) : : : : :

* DSS operation 1503 Days

Power Output

Standby /inspection 579Days

Start

Demanded Power Supply

Stop

6:00 9.937 Bill kWH 38,367 hrs 2,249 times 98.80% Within Allowable Limit

9:00

22:00

24:00

* DSS : Daily Start and Stop ** WSS : Weekly Start and Stop *** Availability : (Actual Power Supply Hours)/(Demanded Power Supply Hours)

Figure 6

T-Point Operation Experience

Operation results at the T-point are shown in Figure 6. As of July 2010 the gas turbine accumulated a total of 38,367 actual operating hours and 2,249 start-stop cycles. MHI G series gas turbine operating fleet has grown to 39 units (66 units sold) and has accumulated more than 1,098,000 actual operating hours and 11,300 starts (as of July, 2010).

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Journal of Power and Energy Systems 4. Japanese National Project

Vol. 5, No. 2, 2011

The Kyoto Protocol come into Gas Turbine Steam Turbine effect in February 2005 in an effort to HRSG prevent global warming. Japan is committed to reduce 6% of the total CO2 emission of 1990 in Japan from 2008 to 2012. Under this severe target, it becomes fundamental to Recirculation improve the thermal efficiency of the cooler gas turbine for GTCC. Recirculation Fan Recirculation Line Based on Japans Basic Act on Energy Policy enacted in 2002, an energy plan was approved by Figure 7 Japanese National Project 1700C Japanese Cabinet in 2003. In Gas Turbine response to this new plan, the Japanese Ministry of Economy, Trade and Industry promotes the development of a high-efficiency gas turbine for power generation. This project pursues an aggressive efficiency target through the development of a 1700C gas turbine. The combined cycle efficiency for this ambitious project targets 62% - 65%. As part of this gas turbine project, core technologies are being developed and commercialized. Key technologies for 1700C gas turbine can be classified into the following six areas; (1) Combustor with exhaust gas recirculation system (2) Turbine cooling technology (3) Super heat resistant material (4) Thermal barrier coating (5) High efficiency, high loading turbine (6) High pressure, high efficiency compressor The current status of the technology developments including analyses and experimental results are reviewed.
Turbine
High Cooling Efficiency Advanced TBC Super Heat Resistant Material High Efficiency, High Loading Turbine

Compressor
High Pressure, High Efficiency Compressor

Combustor
Exhaust Gas Recirculation System

Figure 8

1700C gas turbine design features

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5.1 J series Design Features TIT increase is the key for achieving high combined cycle efficiency but involves the difficult technical challenges that should be overcome through exhaustive R&D efforts and verification test. The J series will operate at an intermediate TIT between the current 1500C (G series GT) technology and the 1700C (Japanese National Project) TIT involved in the Japanese National Project. The main features of the J series GT are: - 1600 C TIT - 23:1 Pressure Ratio - Application of the technology developed in Japanese National Technologies such as; 1. Turbine cooling technology 2. Advanced thermal barrier coating 3. High Efficiency High Loading Turbine The J series compressor is based on Mitsubishis H series compressor. It operates at a higher pressure ratio than the G (23:1 vs. 21:1).
501J (320MW)
Steam Cooled Steam Cooled Low NOx DLNCombustor(s (s) Low NOx DLN Combustor) 16 cans 16 cans Turbine Turbine improved TBC improved TBC Row 1- 4 cooled blades Row 1 4 cooled blades Row 1-3 cooled vanes Row 1 3 cooled vanes -

High Pressure Ratio High Pressure Ratio Compressor Compressor 15 stages 15 stages

Turbine inlet temperature 1600 C C Pressure ratio 23

Figure 9

J series gas turbine design features

5.2 Target Performance for GTCC Incremental improvements in efficiency have been achieved with Mitsubishi G series combined cycle. The J combined cycle is expected to achieve even higher efficiencies (well above 60% LHV, low heating value). The power generation capacity of the J combined cycle will be about 1.2 times that of the G. The use of state-of-the-art technologies developed in the 1700C TIT Japanese National Project (Figure 10) in this 100 C lower TIT flame allows for a smooth transition and validation period.
Turbine Inlet Temperature () G type J type superalloy superalloy Cooling Technology Cooling Technology

Improved Cooling technology +50 +50 Low thermal conductivity TBC+50 TBC +50

Figure 10

Key technologies for higher temperature

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5.3 Structural Design Features of J series Gas Turbine The J series gas turbine maintains the basic structural design used in previous Mitsubishi large industrial gas turbines as shown in Figure 12. The basic structure of J series is similar to the exiting F and G series gas turbine.

Figure 11

J-series gas turbine rotor

An advanced clearance control system was applied on row1 and 2 blade rings for operation with tighter clearances.
F
series

G
series

H
series

J
series

F series

Cold End Generator Drive 2-Bearing Rotor 4-Stage Turbine Individual Combustors Horizontal Split Casing Turbine Air Cooled Blade Cooled & Filtered Rotor Air

G series

H series

Steam Cooled

J series

Figure 12

Mitsubishi large industrial gas turbines proven features

5.3.1 Advanced airfoil compressor The J series compressor has the same air flow rate as the G series. The 23:1 pressure ratio compressor is based on Mitsubishis H series compressor that has a pressure ratio of 25:1. A three dimensional design concept was applied to reduce the shock loss in the front stage and the friction loss in the middle/rear stage in order to achieve higher compressor efficiency. That concept was assessed by 3D-Reynoles-averaged Navier Stokes CFD code. The concept was validated and the blade performance was measured in a three stage high speed research compressor (HSRC). 5.3.2 Steam cooled combustor and evolving air cooled combustion technology The latest combustor technology allows achieving the same NOx level in the original G combustor without applying steam cooling. For NOx reduction, two key technologies

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should be considered: - Cooling air management to reduce the flame temperature while maintaining the turbine inlet temperature - Reduction of the peak flame temperature to decrease the NOx emissions For J series gas turbine, the same combustion technology is used with steam cooling combustor. The target NOx level is as low as G series gas turbine. The steam flow rate can be adjusted to maintain the metal temperature of combustor hardware. 5.3.3 Turbine F-series G-series J-series Metal temperature of Serpentine + Advanced TBC Serpentine Serpentine + TBC Advanced Film Cooling turbine blade and vanes must Advanced Film Cooling Film Cooling Film Cooling remain below the allowable temperature limit to maintain the reliability at 1600 C TIT operation. The row 1 to 4 Serpentine Serpentine Serpentine blades are cooled by coolant Cooling Cooling Cooling Turbulator Angled Turbulator Angled Turbulator discharged from compressor exit with reduced temperature by the outside cooler, while the row 4 blade of G series gas turbine is uncooled. Figure 13 J-series turbine cooling features The advanced cooling technologies, such as optimized shaped film cooling holes developed in the Japanese National Project (Figure 13) are introduced. Through several heat transfer tests as shown in Figure 14, such as measurements of film cooling effectiveness and heat transfer coefficients in the rig tests, the cooling design for these blades and vanes are confirmed carefully. In the final stage of the verification prior to the trial operation, the hot cascade test for row 1 vane were conducted in the test facility. <Component Test> Metal temperature distribution and pressure distribution of the profile and Component Test (Flat-plate) endwall portion were measured with Flat-plate test embedded thermocouple and pressure Low Speed Research Turbine transducers. The measured metal R1B platform temperatures are confirmed to be lower LSRT Middle Pressure cascade Test than the allowable temperature. For performance improvement, the endwall contouring is applied in the row <G-Engine condition> Middle pressure Test 3 and 4 vanes. T-point (G-Engine) Rainbow Test The rotating blade material is made T-point (G-Engine) from MGA1400 alloy. Directionally <J-Engine condition> solidified casting is applied for row 1 to High Temperature Cascade Test 3 blades and conventional casting for row 4 blade. The stationary vane HTC Test (J-Engine) material is made from MGA2400CC T-point (J-Engine) alloy. The MGA 1400 and 2400 were Figure 14 Verification of Turbine cooling utilized in F/G series gas turbine. TBC (Thermal Barrier Coating) is essential for the high performance gas turbine in order to reduce the cooling air flow while maintaining durability. The focus was not limited to the development of advanced TBC compositions, but also to the manufacturing, spray process and confirmation of TBC

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durability on the actual parts. After rig test, the advanced TBC was tested on the current M501G1 row 1 vanes and blades at T-point. In addition, metal temperature was confirmed to be much lower with the advanced TBC than the current TBC. 5.4 Verification Program for J-series gas turbine The first M501J will be tested at T-point. The manufacturing of this unit is scheduled to be completed in October 2010 and its installation at T-Point is scheduled in February 2011. During the trial operation, more than 2,300 instrumentation probes will be installed in the gas turbine, including about 100 sensors in rotating parts. After the trial operation, the operation under the local utility grid will follow under a daily start and stop (DSS) mode. The subsequent commercial M501J (60Hz) will be ready to delivery in 2011 and put into the commercial operation in 2013. The natural frequency of compressor and turbine blades were confirmed from 0 rpm to 3600 rpm in the high speed balancing facility. The rotor vibration level at the high speed balancing machine was confirmed to be much lower than the allowable level. The M701J is the 50Hz of this new class. It was designed as a full scale design of M501J. The validation of the M501J at T-point will provide very useful feedback for M701J.
Strategic Planning R&D / Design Design Implementation

501J
T-Point Verification Test

(60Hz)
Commercial Operation

2011

2013 701J Ready for FOB

(50Hz)
Commercial Operation

2016

Figure 15

Schedule for J-series Gas Turbine

Figure 16

M501J gas turbine rotor installed in the lower casing

6. Conclusion
Restriction in carbon dioxide emissions are generating controversy around the use of hydrocarbon fuels. Compared with conventional coal plants, high efficiency natural gas fired combined cycle plant can reduce carbon dioxide emission by 50%, therefore, the benefit of high efficiency plant usage goes far beyond energy conservation. MHI upgraded existing gas turbine frames targeting higher efficiency and durability. In the mean time, new developments are pursued to produce leap changes in combined cycle efficiency. MHI is actively participating in a Japanese National Project that targets 62 to 65% combined cycle efficiency through the development of a 1700C class gas turbine. Parts of

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the component technologies developed for the National Project are applicable to a new 1600 C class gas turbine called J. With a combined cycle efficiency of over 60%, the J-series GTCC power generation will achieve considerably lower CO2 emissions and contribute to worldwide efforts to reduce global warming. MHI will continue providing products and services that enable 3E expansion and to promote further innovation of our technologies and business such as 1. Ultra-high temperature gas turbine 2. IGCC (Coal Gasification) 3. GTCC + SOFC (Solid Oxide Fuel Cell) 4. Advanced cycles (Carbon Capture/ Nuclear gas turbine) MHI contributes to the realization of the low carbon economy Figure 17 Future Plan of Fossil through these technologies in the Energy Power Generation future.

References
(1) Tsukagoshi, K., Muyama, A., Masada, J., Iwasaki, Y. and Ito, E., 2007, Operating Status of Up rating Gas Turbines and Future Trend of Gas Turbine Development, Mitsubishi Heavy Industries Technical Review, vol.44, No.4. (2) Ai, T., Koeneke, C., Arimura, H. and Hyakutake, Y., 2009, Development of an Air Cooled G class Gas Turbine (The M501GAC), ASME Turbo Expo, GT2009-60321. (3) Takata, K., Tsukagoshi, K., Masada, J. and Ito, E., 2009, Development of Advanced Technologies for the Next Generation Gas Turbine, The International Conference on Power Engineering-09 (ICOPE-09). (4) Koeneke, C., Arimura, H., Masada, J., Ai, T., Kishine, T. and Hara, H., Development of a New 1600 degreeC Turbine Inlet Temperature Large Flame Gas Turbine, ACGT2009. (5) Ito, E., Tsukagoshi, K. Muyama, A., Masada, J. and Okada, I., 2010, Development of Key Technologies for the Next Generation Gas Turbine, ASME Turbo Expo, GT2010-23233.

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