Advancing Technology: High-efficiency gas turbines

General Electric and Siemens are among companies pushing the frontiers of large high-efficiency gas turbines for electricity generation. Target is more than 60% thermal efficiency for combined-cycle power plants.

11/08/2010


Introduction of the newest H-class gas turbines over the past few years is making greater than 60% thermal efficiency a reality for combined-cycle gas turbine (CCGT) power plants. H-class is the largest and most efficient of gas turbines now being produced for electric power generation.

Relatively few manufacturers build these giant machines; among them are Alstom, General Electric, Mitsubishi Heavy Industries, and Siemens. In the forefront of H-class gas turbine development, GE Energy has three installations worldwide at CCGT power plants. GE’s first H-class installation was a 9H system that began service in 2003 at Baglan Bay power station in Wales, U.K. This 520-megawatt (MW) output, 50-Hz system has compiled more than 36,000 operating hours and served as a technology validation site.

Three other 50-Hz GE H-turbine systems are at work in Japan at Tokyo Electric Power Co.’s (TEPCO) Futtsu thermal power station 4. The first system went into service in 2008, while the third one just recently entered commercial operation. “That brings the total H-technology output for three units at the TEPCO site to 1,520 MW,” said Don Hoffmann, advanced combined cycle platform leader, GE Power & Water. A noteworthy sidelight is that Futtsu 4 is part of a larger TEPCO complex that produces more than five gigawatts of power—making it one of the world’s largest gas turbine combined-cycle installations. Besides the three H systems, the site employs 18 smaller GE gas turbines.

GE’s first 60-Hz H system went online in 2008 at Inland Empire Energy Center in Riverside County, CA, accumulating more than 8,000 operating hours. With the recent start-up of a second turbine, the plant has surpassed 10,000 total operating hours, according to Hoffmann. Inland CCGT power plant has maximum net rated electric output of 775 MW.

Modular implementation

Meanwhile, Siemens Energy is approaching completion of a 10-year development program for its 50-Hz H-class SGT5-8000H turbine that weighs in at 440 metric tons and is designed for 530 MW output in combined-cycle operation. Siemens chose a novel, modular commercialization approach by installing the turbine at a working gas power plant—Irsching 4, near Ingolstadt, Germany. Following synchronization to the grid in March 2008, extensive design validation, durability evaluation, and full-load testing in simple-cycle mode has taken place. Some 1,500 operating hours have been achieved in this mode.

In phase 2 of the program, build-out of the combined-cycle plant began, which included civil engineering work for cooling water piping and the heat recovery steam generator (HRSG), where hot turbine exhaust will be fed in combined-cycle operation. Other progress included installation or near completion of most of the steam turbine, condenser, cooling system, HRSG, and electrical and I&C equipment, explained Willibald Fischer, Siemens’ program manager for H-turbines. Fischer adds that most of the mechanical and electrical installation work will be completed by year-end 2010.

Hot recommissioning of the gas turbine and associated combined-cycle systems will follow early next year. “First firing is on schedule for early January 2011 and hand-over to our customer—E.ON Kraftwerke—remains on target for mid-2011,” said Fischer. “Based on final evaluation of hundreds of terabytes of test data, we are very confident to be able to demonstrate in reality what we promised.”

Scaled from its 50-Hz turbine, Siemens has designed a 60-Hz machine (SGT6-8000H) and announced a first sales order of six units in June 2010 (read more online).


Frank J. Bartos, PE, is a Control Engineering contributing content specialist. Reach him at braunbart(at)sbcglobal.net

 


Also see:http://www.controleng.com,%20search%20for%20/

 

- First order for Siemens’ 60-Hz, H-class gas turbine

 

- The hunt for 60+% thermal efficiency

 

- Largest gas turbine: 2,838 sensors, 90 GB data per hour of testing

 

- New, efficient industrial turbines coming



No comments
The Engineers' Choice Awards highlight some of the best new control, instrumentation and automation products as chosen by...
Each year, a panel of Control Engineering editors and industry expert judges select the System Integrator of the Year Award winners.
Control Engineering Leaders Under 40 identifies and gives recognition to young engineers who...
Learn more about methods used to ensure that the integration between the safety system and the process control...
Adding industrial toughness and reliability to Ethernet eGuide
Technological advances like multiple-in-multiple-out (MIMO) transmitting and receiving
Virtualization advice: 4 ways splitting servers can help manufacturing; Efficient motion controls; Fill the brain drain; Learn from the HART Plant of the Year
Two sides to process safety: Combining human and technical factors in your program; Preparing HMI graphics for migrations; Mechatronics and safety; Engineers' Choice Awards
Detecting security breaches: Forensic invenstigations depend on knowing your networks inside and out; Wireless workers; Opening robotic control; Product exclusive: Robust encoders
The Ask Control Engineering blog covers all aspects of automation, including motors, drives, sensors, motion control, machine control, and embedded systems.
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
News and comments from Control Engineering process industries editor, Peter Welander.
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
This is a blog from the trenches – written by engineers who are implementing and upgrading control systems every day across every industry.
Anthony Baker is a fictitious aggregation of experts from Callisto Integration, providing manufacturing consulting and systems integration.
Integrator Guide

Integrator Guide

Search the online Automation Integrator Guide
 

Create New Listing

Visit the System Integrators page to view past winners of Control Engineering's System Integrator of the Year Award and learn how to enter the competition. You will also find more information on system integrators and Control System Integrators Association.

Case Study Database

Case Study Database

Get more exposure for your case study by uploading it to the Control Engineering case study database, where end-users can identify relevant solutions and explore what the experts are doing to effectively implement a variety of technology and productivity related projects.

These case studies provide examples of how knowledgeable solution providers have used technology, processes and people to create effective and successful implementations in real-world situations. Case studies can be completed by filling out a simple online form where you can outline the project title, abstract, and full story in 1500 words or less; upload photos, videos and a logo.

Click here to visit the Case Study Database and upload your case study.