CILEGON COMBINED CYCLE POWER PLANT

Instruction of Mitsubishi Gas turbine

Mitsubishi Heavy Industries Ltd. Takasago Machinery Works

CONTENTS

1. Mitsubishi Gas turbines History and Development 2. Gas turbines Performance 3. Construction Features 4. Detail Structure of Gas turbine 5. Material 6. Gas turbine Cooling System 7. Combustion System 8. Spin Cooling Operation 9. Gas Turbine New Technology

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1. MITSUBISH GAS TURBINES HISTORY AND DEVELOPMENT

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History of Mitsubishi Gas Turbine

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World Wide Experience

As of Sep. 2003

Total Total : : 431units 431units

U.K. 13 Netherlands 1 Slovakia 2 China 10 Syria 4 Italy 5 Turkey 5 Azerbaijan 1 Spain 7 Japan 147 Egypt 2 Kuwait 4 Iran 11 Macao 3 Hong Kong 7 India 10 Algeria 6 Qatar 6 Taiwan 22 Vietnam 3 Saudi Arabia 26 Philippines 7 U.A.E. 6 Malaysia 3 Pakistan 1 Singapore 4 Nigeria 2 Thailand 16 Bangladesh 4

U.S.A. 36 Dominican Republic 1 Brazil 4 Peru 3 Argentina 5 Chile 1

Mexico 17 Honduras 1

Indonesia Indonesia 19 19

Australia 4 New Zealand 1

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First M701F Gas Turbine Started Operation

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Operating Experience of F series Gas Turbine (50Hz)

Japan M701F ~

1 1993

Thailand M701F 2on1~ 2 1996

Chile M701F 1on1~ 1 1999

Japan M701F 1on1~ 4 1999

Turkey M701F 2on1~ 2 2000

Thailand M701F 2on1~ 1 1997

Argentina M701F 2on1~ 1 1999

Viet Num M701F 3on1~ 1 2001

UK M701F 1on1~ 3 2001

UK M701F 2on1~ 1 2001

Singapore M701F 1on1~ 2 2001 This document contains information proprietary to Mitsubishi Heavy Heavy Industries, LTD. It is submitted in confidence and is to be used used solely for the purpose for which it is furnished and returned returned upon request.
This document and such information is not be reproduced, transmitted, transmitted, disclosed or used otherwise in whole or in part without the the written authorization of Mitsubishi Heavy Industries, LTD. MITSUBISHI HEAVY INDUSTRIES, LTD. Takasago Machinery Works

India M701F 1on1~ 1 2001

Bangladesh M701F 1on1~ 1 2001

Argentina M701F 2on1~ 1 2001 MHI BUSINESS CONFIDENTIAL

Operating Experience of F series Gas Turbine (60Hz)

USA 2on1~ 2 1993

Japan 1on1~ 4 1994

Japan 3on1~ 1 1995

Japan 1on1~ 2 1995

Japan 1on1~ 7 1997

Mexico 2on1~ 1 2001

Mexico 2on1~ 1 2001

Mexico 2on1~ 2 2003

Mexico 1on1~ 1 2003

Taiwan 1on1~ 1 2003

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Takasago 330MW Combined Cycle Power Plant Powered by First M501G

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10

2. GAS TURBINES PERFORMANCE

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11

Principle of Gas Turbine

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12

Structure of Gas Turbine

1
MITSUBISHI HEAVY INDUSTRIES, LTD. Takasago Machinery Works

2
MHI BUSINESS CONFIDENTIAL

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13

Mitsubishi M701F Gas Turbine

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14

Gas Turbine Longitudinal Section

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15

Gas Turbine Cycle -Ideal Cycle-

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16

Gas Turbine Cycle Performance

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17

Compressor Performance (1/2)

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18

Compressor Performance (2/2)

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19

Turbine Performance (1/2)

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20

Turbine Performance (2/2)

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21

Gas Turbine Cycle Loss

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Gas Turbine Ambient Temperature Characteristic

22

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23

3. CONSTRUCTION FEATURES

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24

Fundamental Structure of Gas Turbine

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Design Features of F Series Gas Turbine (1/3)

25

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Design Features of F Series Gas Turbine (2/3)

PROVEN FEATURES
A Cannular Type Combustor @ Stacked Disc Type Rotor

26

Torque Pin in Compressor Disc

Turbine Curvic Coupling

Spindle Bolt Disc
Fuel Nozzle Combustor Basket Transition Piece

B Air-cooled Turbine

Torque Pin Curvic Coupling Disc Contact Surface Spindle Bolt C@ Cold End Drive E Tangential Strut

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Design Features of F Series Gas Turbine (3/3)

PROVEN FEATURES
D ROTOR COOLING

27

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28

Proven Design Features of Mitsubishi GT

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29

4. DETAIL STRUCTURE OF GAS TURBINE

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30

Inlet Casing Section

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31

Variable Mechanism for Inlet Guide Vane

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Shenzhen Eastern Power Plant Second Design Meeting

32

Thrust Bearing Structure

A
Drain

Drain Supply

Supply

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Shenzhen Eastern Power Plant Second Design Meeting

33

Journal Bearing Structure

B

Supply

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34

Bearing Seal Structure

FLabyrinth LO Seal

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35

Compressor Casing

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36

Compressor Diaphragms

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37

Combustor Arrangement (Dry Low NOx Type)

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38

Cross Flame Tube

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39

Location of Spark Plug & Flame Detector

Spark Plug Flame Detector

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Compressor & Combustor Casing with Dry Low Nox Combustor

Compressor & Combustor Casing Fuel Nozzle Turbine Casing Basket Bypass Valve

40

Fuel

By pass Air
Combustion Gas

Air

Transition Piece
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41

Fuel Nozzle

(Dry Low Nox type 1/2)

Fuel Gas i Mainj Fuel Oil i Mainj Fuel Gas i Pilotj Fuel Oil i Pilotj

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42

Fuel Nozzle

(Dry Low Nox type 2/2)

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43

Combustor Basket (Dry Low NOx Type)

Cooling Air (Compressor Discharge Air)

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44

Transition piece (Dry Low NOx Type)

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45

By bass Valve Mechanismi 1/2j

Bypass Ring Bypass Body

Bypass Elbow

Connection Rod Actuator

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46

By bass Valve Mechanismi 2/2j

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47

Turbine Casing Assembling

#2 #2` 4 Turbine Vane Cooling Air Supply Flange

Trunnion Bearing

Rotor Cooling Air Bleed Flange Trunnion Arm

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48

Trunnion Support

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49

Turbine Vane Assembly

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Bore Scope Inspection Holes/Thermocouple for Disk Cavity Temperature Measurement

50

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Compressor / Turbine Inter Stage Seal Structure

Pressure Diff. Pressure Diff. Low Pressure High Pressure Compressed Air Seal Air High Pressure Hot Gas Low Pressure

51

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Exhaust Casing Structure & Tangential Strut Structure

52

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53

Exhaust Manifold Structure

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54

Supports for Gas Turbine

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55

Gas Turbine Rotor

Compressor Spindle Bolt

Turbine Spindle Bolt

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56

Compressor Rotor Assembly

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57

Compressor Spindle Blot

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58

Turbine Rotor Assembly

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Comp. Rotor Torque Pin / Turbine Rotor Curvic Coupling

59

Spindle Bolt

Disc

Torque Pin

Disc Contact Surface

Spindle Bolt

Curvic Coupling

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60

Compressor Blade Installation

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61

Structure for Torque Tube Seal

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62

5. MATERIAL

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63

Major Material Used in Gas Turbine

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64

Turbine Blade Material

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65

Turbine Vane Material

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66

Combustor Material

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67

6. TURBINE COOLING SYSTEM

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68

M701F Cooled Vane & Blade

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69

Trend of Turbine Inlet Temperature

1400

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70

Evolution of Turbine Inlet Temperature

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Trend of Mitsubishi High Efficiency Gas Turbine

71

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72

Technology for high Temperature Turbine

M701F

M701D

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Trend of High Temperature Resistant Material Development

73

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74

Trend of Turbine cooled Vane

/701F /701D

/701F

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75

Trend of Turbine cooled blade

/701F

501F/701F /701F
/701D 501D/701D /701B2

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76

Thermal Barrier Coating (TBC)

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77

Structure of TBC

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78

Advanced Turbine Cooling

M701F M701D

M701D M701F

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79

Cooling Method

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80

Film Cooling

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81

Pin Fin Cooling

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82

Impingement Cooling

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83

Turbulator

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84

Row 1 Vane

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85

Row 1 Blade

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86

Row 2 Vane

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87

Row 2 Blade

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88

Row 3 Vane

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89

Row 3 Blade

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90

Row 4 Vane

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91

Row 4 Blade

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92

Secondary Flow System

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93

Turbine Cooling Air Flow System

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94

Turbine Rotor Air Flow

TURBINE ROTOR COOLING AIR FLOW

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95

Turbine Inner Seal Flow

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96

Turbine Outer Seal Flow

PREVENTION OF HOT GAS REVERSE FLOW
COOLING AIR

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97

Temperature Monitoring Location

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98

7. COMBUSTION SYSTEM

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99

Requirement for Reducing NOx Level

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100

Approach for Low Nox Combustion

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Comparison Between diffusion Combustion and premix combustor

101

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102

Mitsubishi Dry Low NOx Combustor

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103

Dry Low NOx Combustor

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104

Dry Low NOx Combustor Basket

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105

NOx Emission Characteristic

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106

Design Concept of Low NOx Combustor

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107

DLN Control System

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108

8. SPIN COOLh NG OPERATION

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109

Characteristics of blade tip clearance

A. Characteristics of tip clearance are estimated for the entire operational conditions including cold start and very hot start. B. Reduction of clearance is observed at compressor blade ring right and left side while the engine restarts under very hot condition due to oval deformation (). C. Reduction of clearance is observed at turbine casing bottom side during re-starting due to cat back deformation ().
: Oval deformation
(Compressor side clearance is critical.)

: Cat back deformation

(Turbine side clearance is critical.)

Blade ring

Casing

Rotor

Rotor

Bottom side Clearance

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Oval deformation of compressor blade ring at rear stage

Just after the shut down of GT, the rear stage compressor blade ring is shrunk rapidly accompanied with oval deformation due to rapid cooling. The rear stage compressor tip clearance each at right and left becomes critical due to the oval deformation. If the GT is re-started or spin under such a condition, rubbing is anticipated. Therefore, it is strongly recommended to re-start or spin the GT after 1.5 hour when rapid shrinkage is recovered.
Compressor Blade Ring

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Cat back deformation of the gas turbine casing

Cat back deformation of the gas turbine casing is caused by the casing metal temperature gradient between top and bottom halves. The casing metal temperature gradient is caused by natural convection. Hot air inside the casing is convected upward. Natural convection inside the casing occurs after shut down of the gas turbine (GT). After a while if the GT is restarted, minimum clearance occurs at bottom side due to the distortion.

111

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112

Countermeasure (Use of spin operation)

In order to reduce the casing thermal distortion, it is recommended to carry out the spin cooling operation after gas turbine shut down. In order to monitor the casing metal temperature difference after shut down and to optimize the spin cooling procedure, thermocouples are installed on each top and bottom casings as shown below.

1.5

Casing metal temperature gradient between top and bottom will be reduced due to spin cooling operation and casing distortion will be minimized. Bottom clearance will be restored due to reduced casing distortion.
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113

Reliability enhancement by spin cooling

MHI established the following guideline for spin cooling and recommend to carry out the spin cooling operation after shut down.
1) The GT cannot be restarted or spun within 1.5 hour after the shut down so as to avoid the compressor blade tip rubbing due to the compressor blade ring oval deformation. (Zone A in Figure 1) 2) The GT can be restarted during 1.5~6 hours after the shut down without spin cooling, provided the casing metal temperature difference is within the criteria. (Zone B in Figure 1) Criteria for turbine casing: 60C / for combustor casing: 35C 3) If the GT is planned to restart during 6~30 hours after the shut down, the spin cooling operation is required. Because the casing metal temperature difference is estimated to exceed the criteria during this period without spin cooling. (Zone C in Figure 1) 4) After approx.30 hours from the shut down, the GT can be restarted without spin cooling operation, provided the casing metal temperature difference reduces within criteria level due to natural cooling. (Zone D in Figure 1) 5) In case of the restart timing of the GT is not predicted, it is recommended to carry out the spin cooling operation 1.5 4.5 according to the standard Figure 1 : Trend of procedure. GT casing metal
temperature difference without spin cooling

Time after GT shut down

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114

9. GAS TURBINE NEW TECHNOLOGIES

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115

Steam Cooled Combustor

Main Fuel Pilot Fuel
Premix Burner Multi Nozzle

Flame Temp. =1500

i Returnj

Air
i

Steam
i Supplyj Return j 1500

Steam Cooling Circuit (MTFIN)

(Return) Steam (Supply)

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Progress of Cooling Method

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Heat Resistant Material Technology (Super Alloy Technology)

117

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Active Clearance Control i Steam Cooled Blade Ringsj

Normal Blade Ring

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Blade Ring Cooling Steam From HRSG

RPM. LOAD [%]

Steam Cooling Passage From Combustor Cooling Outlet

Steam Cooled Blade Rings To Combustor Cooling Inlet

Row 1 Vane

Row 1 Blade

Clearance Verified by Clearance Measurement Large Clearance During Starting Up This document contains information proprietary to Mitsubishi Heavy vy Industries, LTD. It is submitted in confidence and is to be used returned request. Hea used solely for the purpose for which it is furnished and returned upon
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CONFIDENTIAL State Small clearance at Steady

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Leaf seal at Torque Tube

Significant leakage reduction compared to brush seals

Leaf seal location
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Aerodynamically shaped tangential strut cover

Tangential Strut

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Exhaust Diffuser@ 3D CFD Analysis

Mach Number Distribution

Exhaust Flow

Reduced shock wave at leading edge

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