Energy Efficient in Gas-Fired Heat and Power...

© 2016, General Electric Company. Proprietary . All rights reserved.

GE Gas Power Systems

Energy Efficient in Gas-Fired Heat and Power Generation

Attapon Patvivatsiri GE Power March 24th, 2016


© General Electric Company. Proprietary Information. All rights reserved

>62% net CC Efficiency

Gas Turbine rating

H-class

F-class

E-class

9HA

9F

9E

7HA

7F

6F

6B

7E

.02

.01

.06

.05

.04

.03

.04

.03

.03

.01

.03

60 Hz

Geared

50 Hz

299 MW

281 MW

265 MW

145 MW

132 MW

82 MW

52 MW

44 MW

2

GE’s 2016 HDGT portfolio

.02

.01

.06

.05

.04

.03

241 MW

198 MW

91 MW


519 MW 429 MW

346 MW

280 MW

Broad portfolio for efficient , flexible & reliable gas turbines

Combined Cycle rating

774 MW 643 MW

509 MW

419 MW

342 MW

270 MW

508 MW

394 MW

6F.01 Gas Turbine & Application

Technology drives the industry

GE © 2015 – All Rights Reserved 4

• Over 1200 units & 50 million operating hours

• First with single digit DLN

• First to 32k CI / 32k HGP / 64k MI

GE F-Class gas turbines

Source: McCoy Power Reports

… 6F.01 introduced in 2003

35-70MW GT Orders

55

60

65

Gas turbine firing temperature °F

Co

mb

ine

d c

yc

le e

ffic

ien

cy

%

introduced

2003 steam-cooled

introduced

2013 air-cooled

introduced

1986

2300 2600 2000 2900

introduced

1972 50

Technology & plant capability drives industry

GE leads the industry in size & efficiency… driving best economics


Proven F-class technology becoming the segment standard

35-70MW gas turbine units per year

Sources: 1. 1980-2013 McCoy Power Reports, Aeroderivatives introduced from 1990 as “F-Class” 2. GE PGP Marketing Forecast of Gas Turbine Orders next decade

6F benefits from 7F and 9F experience

Value of efficiency moving the segment to F-Class

5

Source: GPS Analysis

50% efficient

Power Plant

Boiler

Traditional

COMBINED Heat and

Power Plant

CHP/Cogen

CHP overview

Heat

Electricity

Cu

stom

er

Cu

stom

er

80%+

efficient

Increasing CHP demand for global industrial growth

Industrial power 10-80MW (GW/year)

'12-'14 15-'17

MENAT

China

ASEAN

Europe

2.9 ~3

ROW

CHP dramatically reduces overall energy expense and power gen Heat Rate

Rus/CIS

Americas

Sources: Navigant, McCoy, P&W Marketing

Excludes ST on combined cycle

© 2015, General Electric Company. Proprietary information. All rights reserved.

6

Gas turbine performance 52 MW net output

38.4% net efficiency (LHV)

1x1 CC performance 76 MW net output


2x1 CC performance 154 MW net output


CHP Performance >80% efficiency

6F.01 Technology & capability

Hot Gas Path • 3 stages advanced and proven HGP materials

alloys • High Tfire capability designed in • 900 starts/ 32k hour inspection

DLN2.5 Combustor • 6 Can-annular combustors

• Dual fuel capability <25ppm NOx

• 32k inspection • Wide fuel capability

Compressor • 3D Aero with 3 variable stages

• 12 stages, 3 Variable Stage Vanes • Field replaceable blades

7 GE © 2015 – All Rights Reserved

600°C

6F.01 Packaged for ease of installation

8 GE © 2015 – All Rights Reserved

Compact footprint

Expanded laydown space for

maintenance

Easy centerline access for rapid

maintenance

NTP to COD < 20 months

Launch Site

• AKEnerji

• Kemalpasa, Turkey

• 2x1 6F.01 combined cycle

GT Validation • 5 months, 161 hours of testing

• 2462 TC, Press and SG sensors

• Testing from FSNL to FSFL

• Confirmed Aeromechanics, Aerodynamics, & Thermal Profiles

Service Validation • CSA coverage… CI, HGP, MI performed

6F.01 Fleet leaders…AKEnerji, Turkey

AKEnerji, Turkey Installation Post validation inspection

2005 2000 2010 2015

COD May’05

Shipment Dec’03, May’04

110,000 Hours

2,250 Starts

Technology Development

Major Inspection

AKEnerji Reference Letter

“Fully satisfied with equipment and services”

99.2% Average Commercial Reliability

*past 4 years

Major Inspection

GE © 2015 – All Rights Reserved

• Disconnected from grid Variable speed, variable load

• Adjustable pressure control

• Large sensor count… 441 aero, 24 clearance, 170 SG

Mapped full operating envelope

• 25%-110% corrected speed covering ambient temperature from -31 to 120 °F and up to 115% load

• Compressor flow & PR capability

• From no load to surge

Validated extreme transients

• Multiple surges

• Stringent grid events

• Fast & peaking starts

Compressor exceeded expectations

Verified & validated design tools & processes

Broad application space & future growth capabilities

6F.01 Validation…Compressor World class, variable speed, full load compressor test facility … GE O&G Massa, Italy

Massa, Italy

Pre

ssu

re r

atio

Corrected flow

Current


6F.01 … Best in segment customer economics

Lower OpEx Best in class CC and CHP efficiency,

64,000 hour major Inspection interval

Lower CapEx Best in class plant $/kw enabled by high gas turbine exhaust temp

Simpler Modular construction for ease of installation and maintenance

Fuel

Flexibility Lean to rich methane gas Liquid fuels, including light crude

Proven Demonstrated long term reliability and availability

© 2015, General Electric Company. Proprietary information. All rights reserved.

11




Gas Turbine rating

H-class

F-class

E-class

9HA

9F

9E

7HA

7F

6F

6B

7E

.02

.01

.06

.05

.04

.03

.04

.03

.03

.01

.03

60 Hz

Geared

50 Hz

299 MW

281 MW

265 MW

145 MW

132 MW

82 MW

52 MW

44 MW

12

GE’s 2016 HDGT portfolio

.02

.01

.06

.05

.04

.03

241 MW

198 MW

91 MW


519 MW 429 MW

346 MW

280 MW

Broad portfolio for efficient , flexible & reliable gas turbines

Combined Cycle rating

774 MW 643 MW

509 MW

419 MW

342 MW

270 MW

508 MW

394 MW


7/9HA gas turbine


Order year

‘05 ‘14 ’19e

% o

f in

du

stry

GT

ord

ers

0

100 H-Class

E-Class

F-Class 45%

27%

9%

11%

19%

43%

12%

12%

Industrial <100 MW

utility

Aeroderivative

9% 13% intermediate

distributed

Industry-leading products & plants

Investing $2B to deliver strongest portfolio & plant capability

‘16 Catalog performance $600 M of value creation vs. ‘15

14

World’s broadest,

most competitive portfolio

55

60

65

Gas turbine firing temperature °F

Co

mb

ine

d c

yc

le e

ffic

ien

cy

%

introduced

2003 steam-cooled

introduced

2013 air-cooled

introduced

1986

2300 2600 2000 2900

introduced

1972 50

Industry orders shifting

towards H-class (% by MW)

H-class fastest growing segment… approaching ½ of industry orders

Technology & plant

capability drives industry

GE leads the industry in size & efficiency… driving best economics

© 2016 General Electric Company - All rights reserved


© General Electric Company. Proprietary Information. All rights reserved 15

HA gas turbine platform evolution Three generations of gas turbine technology

Over a decade of technology advances and 50 million hours of experience

9H ‘03

7/9HA

7F.05 ‘12

9F.05 ‘05

4-stage VGV 4-stage turbine Single crystal alloys

3-stage VGV 14-stage compressor Field-replaceable blades

Note: year denotes first operation

Full load validated

October ‘14

Single crystal alloys DLN 2.6+


Gas… H-class growth transforming the industry

Technology advancing gas industry … saving $50 Million per year of fuel costs per plant


A decade of progress

F-Class

H-Class

>60%

55%

Efficiency

2x per 500 MW CC

Size

Plant CAPEX

Dispatch

1x per 500 MW CC

~4000 hours/year

~8000 hours/year

~$700 per kW

<$600 per kW

$500M per yr per GW*

$550M per yr per GW*

Fuel Expense

* $10/MMBtu gas, 8000 h/y operation, 1000MW plant

55%+

EFFICIENT 60%+

EFFICIENT

=

F class H class

$30B CAPEX SAVINGS

500 HA units vs. F-Class

$8B/year FUEL SAVINGS

2X OPERATING HOURS



Frequency response demonstration Frequency drop response

•Demand change +62 MW in less than <2s

•Gas turbine reacts promptly to power demand (>62 MW/23 seconds)

•Successful load acceptance >20%

Frequency increase response

• Load drop -165 MW in less than <3s

•Gas turbine drops off instantaneously

(>165 MW/4 seconds)

•Successful load rejection 45% to part-load

17

9HA frequency response capability witnessed by Grid Authority


Test cell configuration Full speed full load power train 50Hz and 60 Hz

2009 2008 2011 2012 2014 2015

FSFL test facility developed

Mechanical testing lab

Full scale compressor test

7F.05 validated

9HA validated

7HA validation

Starter motor

Drive motor

Gear box

Advanced compressor

HA production gas turbine

Torque converter

Power train 50 m

‘12: 7F.05 ‘14: 9HA ‘15: 7HA

TIERED TESTING PROGRAM

18



Test train capabilities

Load compressor and gas turbine represent a small and unstable grid,

capable of exploring the highest Rate of Change of Frequency

achievable for a given load imbalance

Mechanical load control vs. electrical grid connection: • Load demand is governed by the ‘load compressor’ • Load production is followed by the ‘prime mover’ = gas turbine A demand vs. power imbalance creates a speed/frequency deviation and load change— just like on a grid, but with much lower inertia (electrical frequency changes are not transmitted ‘instantaneously’ to a prime mover)

Rapid loading and changing of speed is achieved through: • Fast acting load compressor controls (IGV and valves) • Fast responding gas turbine controls (fuel controls)



Compressor operating capability

Complete compressor map with exploration of true capability

MAPPED-OUT FULL OPERATING ENVELOPE • Ambient temperature from -40°C to

85°C • 45 Hz to 55 Hz and up to 115% load • Compressor flow and pressure

capability (surge)

VALIDATED EXTREME TRANSIENT BEHAVIOR • Multiple surges • Stringent grid events • Fast and peaking starts

Operation limit line (OLL)

Compressor operating line

Minimum operation line

9HA COMPRESSOR - TEST STAND


GE’s HA gas turbine exceeds expectations

Test Stand

1 Unit 200 Hours

more valuable

than

115% Output Lower Heat Rate Surpassed Hot Day Performance 10% Lower Turndown 3x nominal Fast Start

2x nominal Ramp Rate Gas variation – doubled -15% NOx Emissions

• Off-grid full speed, full load test capability • Able to operate beyond “real world” limits • Comprehensive validation before FF in field • Enabling rapid acceptance by customers,

insurers & lenders

Field Operation

500 Units 1 Year

GT

Eff

icie

nc

y %

GT MW

Engineering expected

+1% output

+.5% efficiency

Proven Results

21


Comprehensive understanding of design processes, technology & capability


EdF Bouchain: Site works ongoing

Shaftline Site Overview

HRSG and Stack On schedule for Commissioning end of 2015

22

9HA unit #2 site works commissioning

Energy Efficient in Gas-Fired Heat and Power...

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