GE Energy

The 7FA Gas Turbine

“A Classic Reimagined”

GE Gas Turbine Technology Symposium

Greenville, SC
October 2009

Russ Martin
60 Hz Product Manager - Advanced Technology
Heavy-Duty Gas Turbine Combined Cycle
Jim Donohue
Marketing Program Manager - Advanced Technology
Heavy-Duty Gas Turbine Combined Cycle

©2009 General Electric Company. All Rights Reserved. This material may not be copied or
distributed in whole or in part, without prior permission of the copyright owner.
Contents

I. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

II. The 7FA Model Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

GE F Series Gas Turbine Experience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
GE F Series Technology “Firsts” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
The Fleet with the Most Experience. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

III. 7FA Platform Evolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Naming Progression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Performance Evolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

IV. The 7FA Story Continues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Value Proposition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Flexibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Maintainability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

V. Reference Plant Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

VI. Proven Technology and Experience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Combustion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Turbine Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

VII. Validation Plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Component Level Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
System Level Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

VIII.Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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i
The 7FA Gas Turbine: “A Classic Reimagined”

I. Introduction
Today’s power generators find themselves in an uncertain world. Greenhouse gas legislation, fuel prices, renewable
portfolio standards, and financing constraints are but a few of the issues they face. In response to these demands, GE
has continued to evolve its F-class technology, which has been an industry standard for reliable, flexible, and economical
power generation for almost two decades.

The newest addition to GE’s F-class gas turbine portfolio, the 7FA.05 version, delivers greater output and efficiency while
maintaining leadership in reliability, availability and the operational flexibility power generators need to achieve greater
revenue in all operating modes. In developing the newest version of the 7FA, GE has mined the wealth of knowledge that
comes from the largest and most experienced F-class fleet in the industry and combined it with proven technology from
across GE’s broad portfolio of heavy-duty and aeroderivative gas turbines, as well as GE’s aircraft engine models.

II. The 7FA Model Series

GE F Series Gas Turbine Experience
GE’s F gas turbine technology was initially developed in the 1980s. It represented a quantum leap in the operating
temperatures, cooling technology and aerothermal performance of heavy-duty gas turbines. GE’s first F technology
unit entered commercial service on June 6, 1990. As of August 2009, there are more than 700 7FA gas turbines in service
with a cumulative operating experience of more than 19 million fired hours and more than 520 thousand starts. The
hours-based fleet leader has logged more than 126 thousand hours while the starts-based fleet leader has logged
more than 3,400 starts.

7F technology has been scaled to the 50 Hz 9FA machine and the 50/60 Hz 6FA machine. It has also evolved to the
advanced FB technology found in GE’s 60 Hz 7FB and 50 Hz 9FB machines. A grand total of 996 GE F technology units
are now in service with more than 30 million fired hours and 624 thousand starts.

Model Units Hours Starts

6FA 74 2.6+M 31K

7FA/B 715 19.0+M 520K

9FA/B 197 7.3+M 77K

Table 1. GE F-class operational experience.

This experience includes operation in duty cycles ranging from peaking to daily start/stops to base load operation as
illustrated in Figure 1.

GE F Series Technology “Firsts”

GE has continued to develop the F technology over time, and the 7F has been the first to achieve numerous
F technology firsts:

• F technology gas turbine

• 55% thermal efficiency

• 100% reliability…275 day period

• Single digit emissions for NOx and CO

• 99.4% reliability…F technology record

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1
The 7FA Gas Turbine: “A Classic Reimagined”

7FA - FA+e/7FB Fleet Experience

4,500

4,000

Peaking Duty
3,500 157 10 Hours/Start
50 Hours/Start
23% of Fleet
7F - FA
3,000 7FA+ - 7FA+e
Fired Starts

Cycling 7FB
326
2,500 47% of Fleet

2,000

1,500 Base Load

207
1,000 30% of Fleet

500

0
0 10,000 20,000 30,000 40,000 50,000 60,000 70,000 80,000 90,000 100,000

Fired Hours
Figure 1. 7FA duty cycle for 2008 (base load, cyclic, peak).

• Syngas applications

• 700+ units manufactured

• 19+ million operating hours

• 40% load with single-digit emissions compliance

The Fleet with the Most Experience

To summarize, GE can confidently say its F technology has:

• The largest fleet

• The most operational experience

• The most reliable fleet

III. 7FA Platform Evolution

Naming Progression
Over time, as the 7FA evolved, various version and designation nomenclatures have been used to distinguish ratings
and part replacement configurations. In general, the historical “version” progressed as firing temperature incrementally
increased (i.e., 7F, 7FA, 7FA+, 7FA+e), while historical “designations” were assigned depicting frame size, shaft horsepower
and shaft configuration. Going forward, GE has adopted a simplified naming convention as illustrated in Table 2.

The platform will continued to be referred to as the “7FA” model with incremental versions to distinguish significant
rating changes.

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2
The 7FA Gas Turbine: “A Classic Reimagined”

Product Model 7F 7FA 7FA 7FA 7FA 7FA

Revised Version 7F.01 7FA.01 7FA.02 7FA.03 7FA.04 7FA.05

Historical Version 7F 7FA 7FA+ 7FA+e - -

Historical Designation PG 7191 PG 7221 PG7231 PG7241 - -

Table 2. 7FA model naming progression.

Performance Evolution
Figure 2 illustrates the evolution of the 7F technology since its inception. The remainder of this paper focuses on the next
step in the 7FA evolution and how it addresses customers’ needs today and in the future.

220
7FA.05 Version
Compressor 38.5% Eff.
210

200
GT output (MW)

190 7FA.04 Version

38.0% Eff.
7FA+e
180
7FA+ 36.2% Eff.
35.7% Eff.
170
7FA
35% Eff. Combustion/HGP
160
7F
34.5% Eff.
150
’88 ’90 ’92 ’94 ’96 ’98 ’00 ’02 ’04 ’06 ’08 ’10 ’12 ’14
Years
Figure 2. 7F performance evolution.

IV. The 7FA Story Continues

Value Proposition
GE Energy’s newest version of the 7FA heavy-duty gas turbine, the 7FA.05, delivers greater output and efficiency than
earlier versions of the 7FA, while maintaining leadership in reliability, availability and the operational flexibility power
generators need to achieve greater revenue in cyclic and peaking operation.

To help meet customers’ growing needs to generate more power more efficiently, GE Energy introduces the next
evolution of its industry-leading 7FA heavy-duty gas turbine for the 60 Hz power generation regions. By merging a host
of proven technologies mined from across our product lines, the next evolution of the 7FA now offers improvements in
output, thermal efficiency, operability and lower life-cycle costs, all without compromising the high degree of reliability,
availability, and maintainability (RAM), and operational flexibility historically delivered by GE’s F-class fleet.

Using proven technology from earlier GE models, the 7FA.05 version is coupled with a highly advanced 14-stage axial
compressor, providing enhanced performance, operability, and maintainability, in simple-cycle and combined-cycle
configurations.

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3
The 7FA Gas Turbine: “A Classic Reimagined”

Performance
The improved performance and efficiency of the next evolution of the 7FA gas turbine translates into increased revenue
for power generators. GE’s new 7FA delivers greater output with greater efficiency than earlier versions of the 7FA, without
sacrificing the reliability, availability and operational flexibility customers have come to expect from GE F-class technology.
Especially well-suited for cyclic and peaking projects, the 7FA.05 version can generate more than 625 MW in a 207FA
combined-cycle configuration with 57.5% efficiency, and with the backing of GE Energy’s unsurpassed product support.

The application of a larger, more efficient compressor delivers improved output compared to earlier versions by allowing more
airflow, and enhanced efficiency due to its three-dimensional aerodynamic airfoils and hybrid radial compressor diffuser.

Simple Cycle Combined Cycle*

Output 211 627

Efficiency (%, LHV) 38.5 57.5

Heat Rate (Btu/kW-hr, LHV) 8872 5934

NOx (ppmvd @ 15% O2) 9 2

CO (ppmvd) 9 9
*Combined-cycle values assume gas fuel, ISO base load conditions, 1.5" HgA steam turbine
backpressure, 2x1 combined cycle utilizing a GE 207D-11 ST, SCR, no duct firing and no CO catalyst.

Simple-Cycle Gas Turbine Output. The gas turbine output of the 7FA.05 version is incrementally improved over the 7FA.03
version by +33.6 MW (cold day @ 0°F); +35.8 MW (ISO day @ 59°F); and +37.4 MW (hot day @ 100°F) as shown in Figure 3.

Figures 3 and 5 have a characteristic flat output rating from approximately 59°F to 70°F. In this ambient temperature
region, the 7FA.05 gas turbine operates with slightly closed inlet guide vanes and variable stator vanes, which become
opened fully at approximately 70°F. In the region of constant base load output, the exhaust flow will increase, exhaust
temperature will stay approximately flat, and the exhaust energy will increase.

240

7FA.05
220
Improved
SC Output (MW)

Hot Day Output

200 7FA.04 +37.4 MW

7FA.03
180

160

140
-20 0 20 40 60 80 100 120
Ambient Temperature (°F)
Figure 3. Simple-cycle gas turbine output.

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4
The 7FA Gas Turbine: “A Classic Reimagined”

Simple-Cycle Gas Turbine Efficiency. The gas turbine simple-cycle efficiency of the 7FA.05 version is incrementally improved
over the 7FA.03 version by 1.4 points (cold day @ 0°F); 1.4 points (ISO day @ 59°F); and 1.6 points (hot day @ 100°F) as
illustrated in Figure 4.

40%
Improved
7FA.05 Efficiency
39% +1.4 pt
SC Efficiency (LHV)

7FA.04
38%
7FA.03
37%

36%

35%

34%
-20 0 20 40 60 80 100 120
Ambient Temperature (°F)
Figure 4. Simple-cycle gas turbine efficiency.

Combined-Cycle Gas Turbine Output. The plant output of the 7FA.05 version in a 2x1 configuration is incrementally
improved over the 7FA.03 version by +111 MW (cold day @ 0°F); +98 MW (ISO day @ 59°F); and +105 MW (hot day @ 100°F)
as illustrated in Figure 5.

It is important to note that in a fully duct-fired application, the 7FA.05 version can achieve more than 750 MW in a 207FA
configuration.

700

7FA.05 Improved
650 Hot Day Output
CC Net Output (MW)

+105 MW
600
7FA.04

550 7FA.03

500

450

400
-20 0 20 40 60 80 100 120
Ambient Temperature (°F)
Figure 5. Combined-cycle gas turbine output.

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5
The 7FA Gas Turbine: “A Classic Reimagined”

Combined-Cycle Heat Rate. The combined-cycle efficiency of the 7FA.05 version in a 2x1 configuration is incrementally
improved over the 7FA.03 version by 1.2 points (cold day @ 0°F); 1.0 points (ISO day @ 59°F); and 1.2 points (hot day @
100°F) as illustrated in Figure 6.

58.0%

+1.0 pt Improved Hot Day

57.5%
CC Net Efficiency (LHV)
Efficiency

57.0% 7FA.05

56.5%

56.0% 7FA.04

55.5%
7FA.03

54.5%
-20 0 20 40 60 80 100 120
Ambient Temperature (°F)
Figure 6. Combined-cycle heat rate.

Environment
In today’s world of increased concern over climate change and the inevitable tightening of regulatory requirements, the latest
evolution of the 7FA maintains its legacy DLN2.6 combustion system to further improve emissions and operating flexibility.

Superior Combustion Technology. With its industry-leading DLN2.6 combustion system, and a model-based control
system that enables robust accommodation of ambient condition and fuel composition variations, the 7FA.05 version
produces more power by firing at higher temperatures while producing only single digit NOx and CO emissions—from
49% load up to 100% load.

Ecomagination*. Ecomagination is GE’s commitment to imagine and build innovative technologies that help customers
address their environmental and financial needs, such as the need for cleaner, more efficient sources of energy. To join
the ecomagination portfolio, a system must complete the company’s rigorous internal and third-party environmental
and operational evaluation.

The new 7FA gas turbine is part of GE’s ecomagination portfolio. Its improved efficiency and higher output will result
in less fuel consumption and lower emissions on a MW-hr basis than currently available 7FA gas turbines across the
entire ambient temperature range, while maintaining the operational flexibility needed by customers to respond to
varying electricity demand conditions. A typical customer operating a GE 207FA combined-cycle plant with a 7FA.05
gas turbine instead of a 7FA.03 gas turbine for an equivalent net plant output of 627 MW could avoid the emission of
more than 19,000 metric tons of CO2 per year, equivalent to the emissions of approximately 3,800 cars on U.S. roads.

Flexibility
The compressor’s three Variable Stator Vane (VSV) stages enhance operational flexibility by allowing the control system
to adjust compressor airflow to accommodate varying fuel and ambient conditions, or in response to changing
operating conditions.

*Ecomagination is a trademark of the General Electric Company.

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6
The 7FA Gas Turbine: “A Classic Reimagined”

Improved Operability. GE’s 7FA gas turbine provides the greatest operational flexibility in its class, with proven
performance in applications ranging from combined cycle and cogeneration to simple-cycle peaking. Our flexible
performance features can help customers expand their ability to operate based on their own specific business priorities
and market parameters, largely free from the constraints of equipment limitations.

Turndown capabilities ensure operators can run the turbine at its lowest operating level without turning it off, leading to
reduced fuel costs, reduced maintenance, and avoiding emissions spikes and time delays associated with full start-ups.

As base load gas turbine output grows it becomes more challenging for the combustor to achieve the same absolute MW
level of the prior version. However, in this case it should be noted that the MW turndown spread (i.e., base load to minimum
load) is wider for the 7FA.05 version. This is attributed to the additional flexibility of the compressor Variable Stator Vanes
(VSVs). In the spirit of continually improving its products to satisfy customers’ needs, GE is developing improved turndown
capability technologies that are expected to bring the absolute MW turndown of the 7FA.05 version even lower.

150

140 7FA.05
GT Min Turndown (MW)

130

120

110
7FA.04
100
7FA.03
90

80

70

60
-20 0 20 40 60 80 100 120
Ambient Temperature (°F)
Figure 7. Gas turbine turndown.

Fast startup capabilities provide the ability to reduce NOx emissions during low load operation, leading to reduced
operating restrictions based on startup NOx limits and savings based on NOx trading credits.

Fuel heating capabilities allow operation on unheated fuel over an expanded portion of the startup sequence, leading
to reduced fuel consumption and reduced startup times for both cold and warm starts.

Component 7FA.03 7FA.03 w/Extended Turndown 7FA.04 7FA.05

Base Load 175 175 183 211

Min MW 87.5 73.5 97 103

% GT Turndown (ISO) 50% 42% 53% 49%

GT Turndown Spread (ISO) 87.5 101.5 86 108

Table 3. 7FA gas turbine turndown comparison.

*Ecomagination is a trademark of the General Electric Company.

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7
The 7FA Gas Turbine: “A Classic Reimagined”

Improved Dispatchability. For customers considering a cycling power plant, the 7FA.05 version can be outfitted with
Rapid Response, providing fast and reliable starts. Rapid Response is a combined-cycle plant solution that allows
generators to quickly add power-generating capacity during times of peak demand while significantly reducing NOx
emissions (up to 60%) and CO emissions (up to 25%) during each startup.

Fuel Flexibility. The 7FA.05 version is fuel flexible, capable of operating on natural gas fuel with a Modified Wobbe Index
Variation of +/-5% without the need for retuning or other adjustments, and can be also be operated using distillate fuel,
reducing fuel costs by enabling operation with the lowest priced fuel available.

Maintainability
The compressor’s field-replaceable blades, along with additional borescope holes that allow for enhanced coverage,
enable improved maintainability and inspection capabilities and result in reduced outage times.

Improved monitoring and diagnostic capabilities are also included through additional sensors and instrumentation that
monitor blade health, along with advanced algorithms that enhance efficiency predictions.

Removable Compressor Blades. The 7FA.05 version compressor supports in-situ removable rotor blades. The enabling
technology is the circumferential dovetail slot design in contrast to an axial dovetail slot design. The circumferential
dovetail design allows the blades to slide circumferentially for removal at designated locations. Blade locks secure
the blades in position.

Figure 8. Removable compressor rotor blades.

Improved Inspectability. The 7FA.05 version compressor casing includes improved inspection capability by the addition
and repositioning of borescope holes. The 7FA.05 version has three borescope hole locations on each stage as compared
to two per stage on the prior versions.

Borescope Locations Top

10 O’Clock

Visible 2 O’Clock

Visible with Robot

Figure 9. Enhanced borescope inspection.

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8
The 7FA Gas Turbine: “A Classic Reimagined”

Enhanced Sensors. New and improved GE proprietary sensors have been added to the 7FA.05 version to support improved
measurement accuracy for performance and operability as well as advanced prognostic capability leading to improved
reliability and availability.

• New and improved GE proprietary sensors have been added:

– Corrosion monitoring for inlet filtration effectiveness

– Blade health monitoring for prognostic anomaly detection

– Variable Stator Vane positioning for enhanced performance

• Existing sensors have been improved for enhanced performance:

– Inlet Guide Vane positioning

– Emissions monitoring

– Compressor flow

– Bleed valve flow

Advanced Monitoring & Diagnostics. The 7FA.05 version incorporates new monitoring and diagnostics capabilities
to help operators better characterize the operation of their gas turbines and determine the condition of key components.
This improved capability will enable the Mark* VIe control system to improve performance and provide operators with
unprecedented diagnostic and prognostic capabilities.

V. Reference Plant Considerations

The 7FA.05 version has minimal impact on customers’ existing 7FA reference plant designs. Minor changes are needed to
accommodate the higher airflow, including a slight increase in the size of the inlet and exhaust, but key parameters such
as the required fuel gas pressure and guaranteed noise level remain unchanged.

Inlet
Scaled for flow increase Cooling and Sealing Air
Re-routed piping

Exhaust
Scaled for flow increase

Gas Fuel System

Scaled for fuel flow increase

Oil Pumps
Lube and hydraulic scaled for flow Gas Turbine Base
Reconfigured for VSV/IGV accommodation

Figure 10. Reference plant design changes.

*Mark is a trademark of the General Electric Company.

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9
The 7FA Gas Turbine: “A Classic Reimagined”

VI. Proven Technology and Experience

The 7FA.05 version builds upon the heritage of proven low risk technology from other GE platforms to achieve a more
efficient, flexible machine. The technologies chosen for the 7FA.05 version have been demonstrated in other GE gas
turbine platforms and leveraged for the 7FA.05 version as depicted in Table 4.

Platform Introduction Units Hours Starts Technology Leveraged

B / EA ‘70s 1120 32+ Million 850K+ Materials

7 / 9FA ’91 / ‘92 1170 30+ Million 600K+ All

7 / 9FB ’02 / ‘05 43 190,000+ 5,900+ HGP

7 / 9H ’08 / ‘03 6 32,000+ 150+ Compressor / HGP

6C ‘05 2 57,000+ 470+ Compressor

GE10 ‘03 254 1+ Million 26K+ Compressor

Table 4. 7FA.05 model version configured from GE experience base.

Compressor
GE's most advanced high efficiency compressor technology, based on the 6C and H platforms and built with GE Aviation
compressor technology practices, has been incorporated into the new 7FA turbine. The 7FA.05 version technology consists
of 14 stages specifically modeled for a higher flow rate, enabling greater output.

The airfoil design is based on the proven aerodynamic configuration of the 6C. The airfoils utilize a three-dimensional
aerodynamic configuration for improved efficiency. The first three stages of the compressor contain variable stator
vanes that provide the gas turbine with a wider operating envelope. The compressor flow path has been configured to
accommodate inlet conditioning with improved leading edge erosion tolerance.

The rotor is bolted steel construction with two sets of durable concentric tie bolts specifically planned to improve the
aerodynamic flow path. The rotor blades and wheels incorporate a circumferential dovetail that permits removing
the blades without pulling the rotor from the casing, thereby improving maintainability.

The compressor casing has been built to match the rotor and the existing DLN2.6 combustor interface. The casings
accommodate an advanced Blade Health Monitoring (BHM) system for stages 1 through 3. Additional borescope holes
have been included for enhanced inspection coverage.

Table 5 identifies the major components of the compressor and how the technology was borrowed from other GE
platforms. A check mark signifies previous experience with the material used in the 7FA.05 version, whereas a green
shaded background signifies prior model experience.

Combustion
The 7FA.05 version will employ the proven DLN2.6 combustor. The combustor has more than 12 million hours and
350,000 starts of operational experience. Minor modifications to the DLN2.6 combustion system will be required for
improved output and efficiency. Upgraded fuel nozzles will allow for a higher fuel flow rate and the transition-piece
cooling flow has been improved. Combustion lab tests have demonstrated emissions, durability, operability, dynamics
and exit profiles for these minor modifications.

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10
The 7FA Gas Turbine: “A Classic Reimagined”

Component Comment B/E FA FB 6C H GE10

VSVs 3 Variable Stator Vanes   

Rotor Bolted, 2 Tie Bolt Rings   

Wheels Circumferential Dovetails      

Blades Increased Stage Loading      

Casings Match Rotor and DLN2.6      

Diffuser Hybrid Radial Flow Path   

Bearings Non-integral w/fwd Case      

= Materials experience, Green = model experience

Table 5. 7FA.05 version compressor model experience.

Component Comment 6/7/9FA Comment

Liner / Flow Sleeve DLN2.6 model  No change

Transition Piece TP cooling pattern adjusted for radial diffuser flow distribution  Minor mod

Caps DLN2.6 model  No change

End Cover DLN2.6 model  No change

Fuel Nozzles Fuel injection peg adjusted for higher fuel flow rate  Minor mod
= Materials experience, Green = model experience
Table 6. 7FA.05 version combustion model experience.

Turbine Section
The turbine section of the 7FA.05 version capitalizes on the recent 7FA.04 Hot Gas Path advancements. FB technology
and experience have been used in the design. Noted features are:

• Three-dimensional aerodynamics airfoil shapes for the stage 1 nozzle and stage 1 bucket improving efficiency

• More efficient stage loading

• Improved cooling and sealing for improved efficiency

• Improved clearances for improved efficiency

• Nominal Tfire increase that still remains well within the FA experience

Materials. FB materials have been employed for the stage 1 nozzle and stage 1 bucket while H material has been
used for the stage 2 nozzle. The higher temperature-capable materials still operating in FA firing temperatures will further
improve the successful experience of the 7FA wear modes for low cycle fatigue, oxidation and creep, thus supporting
longer life and reduced repair costs.

Configuration. The first and second stages of the turbine section will consist of minor modifications to the 7FA.04 version
hardware to increase the flow passing capability. The third stage and distance piece will utilize a 7F Syngas design. The
turbine casing remains unchanged.

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The 7FA Gas Turbine: “A Classic Reimagined”

Component Comment B/E 7/9FA 7/9FB 6C 7/9H GE10

Stage 1 7FA.04 version    

Stage 2 7FA.04 version    

Stage 3 7F Syngas version     

= Materials experience, Green = model experience

Table 7. 7FA.05 version turbine model experience.

VII. Validation Plans

The latest evolution of the 7FA gas turbine will be validated via a comprehensive program of component level, system
level, and fleet level testing. GE is the only gas turbine OEM that has the unique combination of aviation, aeroderivative,
and heavy-duty gas turbines product lines. This breadth of model, manufacturing, and operational experience, coupled
with the world-renowned capabilities of our Global Research Centers, enable GE to perform comprehensive validation
testing and pre-and post-test analyses.

Component Level Testing

The first step of the validation testing program is component level testing. Although the 7FA.05 version employs proven
technology, GE recognizes that robust configurations depend upon a rigorous program to ensure all components are
tested in the actual environments they will see in service.

Many of the components used in the 7FA.05 version have been field tested on a retrofit basis in existing 7FA.03 version
machines. Examples of this include the combustor transition piece and combustion liner, which were introduced in 2006
and currently have more than 13.9 million hours and 380 thousand starts.

Other components, such as the compressor diffuser, will be initially tested in test rigs at GE facilities prior to being
incorporated into system level tests.

System Level Testing

After component level tests are complete, system level tests are performed in order to fully understand interactions
among components.

As mentioned previously, the DLN2.6 combustor has been slightly modified to accommodate higher mass flow. The
modified combustion system will be tested at the GE Greenville, South Carolina Combustion Laboratory prior to being
incorporated into full unit system tests.

A system level test of the turbine section hot gas path components was conducted in the first half of 2008 as a field
retrofit of an existing 7FA.03 version turbine at a customer site in Asia. These components are expected to accumulate
close to 20,000 hours before the first 7FA.05 version is put into commercial service.

GE is constructing a unique Full-Speed Full-Load test facility at its Greenville facility. The first system to be tested in
this facility will be the 7FA.05 version compressor. Using a unique and proprietary power train, GE will be able to fully
characterize the performance of the compressor, including aeromechanics, performance, and surge line mapping.

Following characterization of the compressor, GE will combine the compressor with the 7FA.05 version DLN2.6 combustion
system and 7FA.05 version turbine section and perform a Full-Speed Full-Load test of the complete 7FA.05 version gas
turbine prior to shipping the first commercial unit. This testing will utilize extensive instrumentation to demonstrate
performance, aeromechanics, combustion dynamics, off-frequency capability, and dual-fuel capability. This validation
approach will enable GE to fully characterize the 7FA.05 version under real-life conditions, but in a laboratory setting.

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The 7FA Gas Turbine: “A Classic Reimagined”

The final stage in the system level testing consists of precision performance testing as part of the normal commissioning
activities and a fleet leader inspection program. This inspection program will consist of advanced Monitoring & Diagnostics,
both onsite and remotely, coupled with a program of enhanced borescope inspections designed to be as unobtrusive to
customer plant operations as possible.

VIII. Conclusion
GE’s 7FA is the most experienced F-class gas turbine in the world. The 7FA fleet has more units in service, and has
accumulated more operating hours and starts than any other F-class gas turbine. GE has utilized the wealth of knowledge
that comes from this F-class operating experience and combined it with technology from across GE’s broad portfolio
of heavy-duty and aeroderivative gas turbines, as well as GE’s aircraft engine models, to develop the 7FA.05 version
gas turbine.

The 7FA.05 version has been configured to have a minimal impact on existing customer reference plant designs. Minor
changes are needed to accommodate the higher airflow and associated output, but key parameters such as the required
fuel gas pressure and guaranteed noise level remain unchanged.

The 7FA.05 version delivers increased output and efficiency, which are of course highly valued in today’s competitive
power generation segment, but does so without compromising the world-class operational flexibility, reliability, and
availability of the 7FA. The improved performance and operational flexibility have enabled the 7FA.05 version to become
part of GE’s ecomagination portfolio, a rigorous internal and third-party environmental and operational evaluation.

Prior to delivering the first unit to a customer, the 7FA.05 version will undergo a battery of component level, subsystem
level, and system level tests, culminating in a Full-Speed Full-Load test in a new state-of-the-art test facility being
constructed at GE’s Greenville, South Carolina, gas turbine manufacturing and test center of excellence. This testing
will enable GE to fully characterize the 7FA.05 version under real-life conditions, but in a laboratory setting.

GE’s commitment to the 7FA gas turbine is a testament to the confidence GE has in this industry workhorse to continue
to serve the wide-ranging needs of its customers in an ever changing and extremely competitive segment.

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The 7FA Gas Turbine: “A Classic Reimagined”

List of Figures
Figure 1. 7FA duty cycle for 2008 (base load, cyclic, peak).

Figure 2. 7F performance evolution.

Figure 3. Simple-cycle gas turbine output.

Figure 4. Simple-cycle gas turbine efficiency.

Figure 5. Combined-cycle gas turbine output.

Figure 6. Combined-cycle efficiency.

Figure 7. Gas turbine turndown.

Figure 8. Removable compressor rotor blades.

Figure 9. Enhanced borescope inspection.

Figure 10. Reference plant model changes.

List of Tables
Table 1. GE F-class operational experience.

Table 2. 7FA model naming progression.

Table 3. 7FA gas turbine turndown comparison.

Table 4. 7FA.05 version configured from GE experience base.

Table 5. 7FA.05 version compressor model experience.

Table 6. 7FA.05 version combustion model experience.

Table 7. 7FA.05 version turbine model experience.

References
Availability & Reliability Source: ORAP®; all rights reserved: SPS®.

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©2009, General Electric Company. All rights reserved.

GEA17911 (10/2009)