Gt product overview 10 oct 2002


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  • This slide provides an overview highlighting the proud heritage of GE gas turbines (over 6000 and 200 million fired hours) and the GE commitment to continue this legacy by investing and developing the latest new products (e.g.., “H” gas turbine) and utilizing the latest state of the art equipment (e.g.., bucket machines, new lathe in rotor assembly, new test stand 8).
    It lets the audience know that Greenville is “The World’s Largest and Most Modern Gas Turbine Manufacturing Facility”.
    You can ask the audience if they have had the opportunity to visit competitor facilities and will they confirm this statement?
  • GE has unique technical resources as it can draw from the developments at it’s GE Aircraft Engines and Corporate Research & Development Center for such things as advanced cooling techniques, improved sealing methods, special high-strength alloys, superior high-temperature vacuum plasma spray coating, and sophisticated design and analysis tools. This has helped significantly in the development of and enhancement of GE gas turbines including F technology.
    Notes: Competitors have needed to purchase technology from outside sources to develop their latest products: Westinghouse/MHI/Fiat from Rolls Royce; Siemens from Pratt-Whitney; and ABB from MTU (Russian Technology)
    When competitors’ technology has design problems, who will fix them?
  • One of the features of GE’s gas turbines is that the models are evolved – and the 7EA is a good illustration of that philosophy.
    Starting with the 7B nearly 30 years ago, the basic frame7 has been uprated several times to where it is today – the 7EA with over 200F more in firing temperature and almost double the output.
  • The 84 MW MS7EA fires at 2035 F at a 12:1 PR.
    The model EA was first introduced in 1985 and now has over 500 units in operation.
  • The 84 MW MS7EA fires at 2035 F at a 12:1 PR.
    The model EA was first introduced in 1985 and now has over 500 units in operation.
  • The F machines have a long history starting with the introduction of the first 7F in 1987, followed by the 9FA – a 1.2 geometric scale of the 7F - in 1991, the 6F – a .69 scale - in 1993, and now the 7FB..
  • The Launch Customer is Reliant Energy and the launch Site is a 307FB configuration rated at 844 MW
    Site construction has started and we plan to have a SC Full Speed Full Load test in the 2Q of 2002.
    Then, the remainder of the PP will be completed with COD planned for 2Q 2003.
    The steam turbine design is the same as that used for our 3x7FA’s – a 3-pressure level reheat GE D11..
  • Also, if we were to look at the demographics of how the F machines are applied, a good measure of which would be the number of hours and starts on the fleet, it would look as shown here. (describe plot)
    As you can see, these machines are used in a wide variety of ways from peaking, to cyclic, to base load duty.
    This oldest and largest of fleets, with over 4.1 million fired hours, and with a wide variety of applications, provides for an extensive statistical database upon which to improve the Reliability of the design. An we want to take advantage of that Industry Leading Reliability Experience on the 7FB.
  • Orders (in GW’s) for Gas Turbines has increased significantly over the last few decades.
    Initially, gas turbines were purely simple cycle, but in the 1970’s, the use of GT’s in combined cycle appeared in the market place.
    Today, due to the increased efficiency afforded by CC Power Plants, this configuration has become the predominate one.
  • The main building is divided into 5 main bays shown horizontally on this layout that are specifically sized to support each phase of the manufacturing process. The first bay at the bottom of the slide produces blades and buckets, the next bay up does rotor machining and assembly. The middle bay rotor machining and stator machining and arrangement, then rotor assembly, unit assembly and accessory base assembly. And the last bay, nozzle manufacturing and manufacturing support. The combustion manufacturing, as mentioned previously, is in a dedicated building and the material distribution center supports the entire plant.
    The tour today will stop a 23 key locations where you will hear a brief explanation of the work done in that area. In order to see all of the major plant operations in the short time available, the tour will start “shotgun fashion.” Each group will stop at the same locations, just in a different order.
    Safety glasses will be provided for your use during the plant tour, however, we need your cooperation in not wearing sneakers, tennis shoes, sandals or other soft or open toed footwear since these are prohibited in the plant. Please wear closed hard soled shoes for your factory tour today.
  • 5 Models are - 7EA, 7FA+enhanced, 9FA+enhanced, 7H and 9H
    7EA is 85 Mw and 9FA+e is 255MW
    The steam cooled H machines are Combined cycle machines only
    Many of our Business associates have no invested in expensive tooling to make and assembly rotors and/or hot gas path parts so we supply those parts.
  • EHS very important-
    Low illness/injury rate
    Environmental compliance- Manufacturing actually moving toward more environment friendly machining (Grinders that use water based lubricant/coolant, Wire Electrical Discharge Machining that uses Demineralized water as a coolant)
  • GE giving back to the community through volunteerism and charitable giving
  • The H program has been a collaborative effort including GE Power Systems, Aircraft Engines, and Corporate Research and Development with the support of the US Dept. Of Energy
    The H program focus has been on the development of a high technology GT for the purpose of increasing overall CC efficiency and power density while minimizing emissions - translating, ultimately, into lower COE.
  • The H technology will be the first Gas Turbine CC Technology to be capable of 60% Net Thermal Efficiency
    The innovative enabling technology which most facilitated this goal is steam cooling of the HGP components. With steam cooling and with a firing temperature increase, we are able to increase efficiency and power density AND do so while maintaining lowNox levels.
    Let me talk a little more specifically about this last important point..
  • ..and that’s exactly what steam cooling of the stage 1 nozzle accomplishes. What I am showing on the left would be a typical advanced technology air cooled stage 1 nozzle and on the left a similar nozzle segment with steam cooling.
    With the air cooled nozzle, the cooling air mixes with the hot working fluid as it exits the nozzles cooling passages which dilutes the hot gas path air by about 280 F.
    With the closed loop steam cooled nozzle, the steam is circulated but not mixed with the hot working fluid. Rather the steam cools the nozzle and the super heated steam is then recirculated to the ST for bottoming cycle expansion.
    In this way, the steam cooled nozzle reduces the temperature drop to just 80F - a 200 F improvement in firing temperature with no effect on combustion temperature, that is, more succinctly, the steam cooled nozzle is the primary element for converting a 9ppm Nox machine fired at 2400 F to a 9ppm Nox machine fired at 2600 F!
  • 1.     9H Launch
    For the 9H, the Launch site is at Port Talbot in Wales, where the project is being jointly developed with British Petroleum/Amoco.
    The plant design is configured for a Single shaft STAG 109H rated at 480 MW.
    Commercial Operation slated for the end of that 2002.
    Important milestone have been reached this year, with the trucking of the H gas turbine to site and the unit installation onto the foundation taking place only days ago. 
  • Unique and Innovative Solution to Meet Customer Needs – Steam Cooled Gas Turbine Allows Higher Efficiency and Power Density without Increased NOx
    Product Based on GEPS / GEAE Experience and Proven Technology
    Gas Turbine Combines FA Proven Features with H Technology Improvements
    Leverages GE’s Single Shaft STAG Experience to Create a Highly Integrated CC System
    Most Comprehensively Tested Industrial Gas Turbine
    Controlled Introduction Strategy – Commercial Offerings Following Launch projects
  • Gt product overview 10 oct 2002

    1. 1. GE Power Systems Heavy Duty Gas Turbines Rich Smith Gas Turbine Product Line Leader GE Energy Services
    2. 2. Gas Turbine 10/07/ GE Power Systems GE Company Proprietary
    4. 4. GE Gas Turbines GE Power Systems • Productivity and Technology Leader! • A Fleet of More Than 7000 Gas Turbines! • Over 200 Million Fired Hours! • Support Global Market World’s Largest GT Factory 10/07/ GE Company Proprietary
    5. 5. Early Gas Turbine Applications GE Power Systems First American Jet Flight with Two GE I-A EnginesOctober 2, 1942 First Gas Turbine First American Gas For Power Generation Turbine Electric Locomotive (4500 hp) (3500 kW) - 1949 - 1948 Over 60 Years Gas Turbine Experience! 10/07/ GE Company Proprietary
    6. 6. Technology Overview GE Power Systems Uses Proven GE Aircraft Engine Advancements Compressor Aero Combustion Advanced Cooling Computer Design Tools High-Strength Alloys Leverage Aircraft Technology and Design Tools 10/07/ Turbine Aero GE Company Proprietary
    7. 7. Current Heavy-Duty Gas Turbine Product Line GE Power Systems Output MS9001H MS7001H MS9001FB* MS7001FB MS9001FA MS7001FA MS9001E MS7001EA MS6001FA MS6001B MS6001C Combined Cycle MW Hz 480 50 400 60 413 50 280 60 391 50 263 60 193 50 130 60 118 50/60 64 50/60 63 50/60 Simple Cycle MW Hz 256 172 126 85 76 42 42 * 109FB Configuration Includes GE HEAT TM Steam Turbine 10/07/ GE Company Proprietary 50 60 50 60 50/60 50/60 50/60
    8. 8. MS6001C GE Power Systems MS6001C Evolution of 40 MW Class Not to Scale Leveraging the Experience of Over 800 MS6001B Units 10/07/ GE Company Proprietary
    9. 9. 6C – Performance GE Power Systems 6B Output 41.7 MW 42.3 MW Efficiency 31.9% 36.3% Net Output 130.7 MW 126.7 MW Net Efficiency Simple Cycle 6C 49.8% 54.4% (206 Configuration) Combined Cycle 10/07/ Optimum Combined Cycle Performance GE Company Proprietary
    10. 10. MS7001E - Evolution GE Power Systems Output (MW) 100 7EA PG7111 Tf = 2020 F 157 Units 80 7C PG7931 Tf = 1950 F 12 Units 60 7B PG7821 Tf = 1800 F 232 Units 40 1970 7E PG7981 Tf = 1985 F 138 Units Y/ OG OL CHN TE 1975 1980 7EA PG7121 Tf = 2035 F 142 Units 7EA PG7851 Tf = 1985 F 69 Units CE MAN R RFO PE 1985 ON UTI L EV O 1990 1995 Over 14.7 Million Fired Hours - Technology Evolution Continues 10/07/ GE Company Proprietary
    11. 11. MS7001EA – Performance and Experience Performance • • • • • • OUTPUT (ISO) Experience 85.4 MW HEAT RATE (LHV) 10,420 Btu/kWh PRESSURE RATIO 12.7:1 NOM. FIRING TEMP. 2000+ °F SHAFT SPEED EXHAUST TEMP. GE Power Systems 3,600 RPM 998 °F • 1985: First MS7001EA Shipped • Today: – Over 600 units ordered or operating, Over 27 GW operating – Range of applications: »Mechanical Drive »Simple Cycle »For Base or Peak Load – Fuel Flexibility: »Natural gas »Crude oil »Distillate »Liquid Natural Gas »Process Gas Over 5 Million Fired Hours & 100,000 Starts 10/07/ GE Company Proprietary
    12. 12. MS9001EA – 50Hz Performer Simple Cycle Performance • • • • • OUTPUT (ISO) 126.1 MW HEAT RATE (LHV) 10,100 Btu/kWh PRESSURE RATIO 12.6:1 SHAFT SPEED 3,000 RPM EXHAUST TEMP. 1,009 °F GE Power Systems • 50 Hz Workhorse • Range of applications: – Simple Cycle – Combined Cycle – For Base or Peak Load • Fuel Flexibility: – Natural gas – Crude oil – Distillate – Liquid Natural Gas – Process Gas 350 Units - Over 8 Million Fired Hours of Service 10/07/ GE Company Proprietary
    13. 13. F Family of Gas Turbines 1987 1988 GE Power Systems GE Presents 7F 7F FSNL Testing 7F Factory Load Testing 1989 1990 Introduction of 9F (1.2 Scale of 7F) 1991 9F FSNL Testing 1992 9F Testing at Load 19 93 1993 First 9F in Commercial Operations 1994 Compressor and Turbine Issues occur 1995 First 6FA assembled 1997 GE exceeds 1 million hours of “F” operation 1999 GE Introduces 7FB 2001 GE reaches 4 million hours of “F” operation 7FB FSNL Testing GE reaches 6 million hours of “F” operation 9FB & 6C Introduced 7FB COD 2002 2003 10/07/ First 7F Plant in operation (Combined Cycle) 6FA Program Begins (0.69 scale of 7FA) GE Company Proprietary Successful Sustained Program
    14. 14. F Technology Evolution 9FA 7F 1260 C 9FA+e 7FA+ 1316 C 7FA 1287 C 9FB 7FA+e 1327 C 7FB 1370+ C Net CC Efficiency 57 55 CC 53 i ef f 9FA+e: PR=15.5, 24 NOx 1500 y nc cie G 9FB: PR=18.5, 24 NOx 1450 1400 ure perat tem firing T 1350 1300 51 1250 1986 1988 1990 1992 1994 1996 1998 2000 2002 2004 Firing Temperature (C) 9F 59 GE Power Systems 2006 Higher Firing Temperature Enables Higher Combined Cycle Performance 10/07/ GE Company Proprietary
    15. 15. 7FB (60 Hz) GE Power Systems 107FA* 107FB* Efficiency (Net Plant) 56.0 % 57.3 % Output, MW CC 262.6 280 9 25 NOx , ppm * 7FB and 7FA Are Parallel Product Offerings Over 2% in Combined Cycle Efficiency Improvement with Higher Gas Turbine NOx 10/07/ GE Company Proprietary
    16. 16. 7FB Launch Site GE Power Systems 307FB Power Plant 7FB Gas Turbines Comb Gen C Air C Gen Air Gen T Comb T Comb C T D11 Steam Turbine Exhaust to Stack HRSG Exhaust to Stack HRSG Exhaust to Stack HP HRSG Air December 2001 February 2002 COD 2Q03 • Reliant Energy, Hunterstown, PA – 307FB Power Plant – 844 MW 10/07/ Full Speed Full Load Testing Complete GE Company Proprietary IP/LP Gen
    17. 17. 9FB (50Hz) GE Power Systems 109FA* Efficiency (Net Plant) Output, MW CC NOx , ppm (mg/Nm3) 109FB (w/ HEAT 56.7 % 58.0 % 390.8 412.9 24 (50) 24 (50) TM ST) * 9FB and 9FA Are Parallel Product Offerings 1 Point Combined Cycle Performance Improvement and 20 MW Output Increase 10/07/ GE Company Proprietary
    18. 18. Advanced “F” Technology GT Experience Installed Base Plus ... Commitments & Orders GE Power Systems GE Leads Advanced Technology Field Experience > 900 6.3 Million Fired Hours In Commercial Operation 479 Tfire > 2300 F > 8000 Hrs191 e As of September 26, 2002 10/07/ A B C D GE Company Proprietary
    19. 19. Fired Starts Fleet Experience Demographics GE Power Systems 12 Years of Operating History F/FA Fleet Experience 3,000 6FA 7F/FA 9F/FA 10 Hours/Start 50 Hours/Start Peaking Duty 2,500 27% Of Fleet 2,000 1,500 Cycling Duty 37 % Of Fleet 1,000 Base Load 500 36 % Of Fleet 0 0 5,000 10,000 15,000 20,000 25,000 30,000 35,000 40,000 45,000 50,000 55,000 60,000 65,000 70,000 75,000 80,000 Fired Hours 10/07/ Wide Range of Application Indicates Robustness GE Company Proprietary
    20. 20. Gas Turbine Manufacturing Operation GE Power Systems • Originally Built 1968 • Grew in 1972 • 342,000 ft2 (32,000 m2) • 654,000 ft2 (61,000 m2) • 200 Employees • 1100 Production Employees • 50 Salaried Employees • 400 Salaried Employees • Capacity 30/year • Capacity 60/year 10/07/ The Early Years GE Company Proprietary
    21. 21. 1987-1989 Consolidation & Modernization GE Power Systems Core Technology Rotors Blades Assembly & Test Buckets Combustion Hardware Nozzles Maintain Technology and Quality Leadership 10/07/ GE Company Proprietary
    22. 22. 1990-1993 Capacity Expansion GE Power Systems • 1,040,000 ft2 (97,000 m2) • 1700 Production Employees • 400 Salaried Employees • Significant Hot Gas Part Capacity Increases • Major Machine Tools Added • Plant Capacity 100 Units/Year Support Increased Market Demand 10/07/ GE Company Proprietary
    23. 23. GT COE Evolution 98-99 GE Power Systems • Begin migration of Engineering Functions • Factory space - 1,300,000 ft2 (121,000 m2) • 1900 Production Employees • 800 Salaried Employees Integration with Design Engineering 10/07/ GE Company Proprietary
    24. 24. Demand for Gas Turbines GE Power Systems 350 300 GT Orders (GW) 250 200 CC GW 150 SC GW 100 50 0 1950's 10/07/ 1960's 1970's 1980's 1990's Huge Increase in Orders Combined Cycle Becomes Technology-of-Choice GE Company Proprietary
    25. 25. Greenville GT COE - Current GE Power Systems • Factory space - 1,550,000 ft2 10/07/ • 1900 Production Employees • 1400 Salaried Employees Greenville now GT Center of Excellence for Design, Sourcing, and Manufacturing GE Company Proprietary
    26. 26. The Greenville Six Sigma Journey DPMO/Sigma 8,500 4.44 4.48 4.52 600 DPMO 4.20 5,000 4,048 2,500 4.00 2,501 1,663 1,454 1,264 0 3.80 3.60 '96 '97 '98 '99 756 23X 4.40 4.15 3.89 Projects per Year 700 4.31 7,500 800 4.60 '00 '01 Sigma Level 10,000 GE Power Systems 581 483 500 437 400 285 300 200 100 33 0 1996 1997 1998 1999 2000 • Continuous Improvement • Process Improvements a Way of Life • Cross Functional Teams • Foundation for Capacity Improvement 10/07/ Six Sigma . . . The Way We Run Our Business GE Company Proprietary 2001
    27. 27. Greenville Productivity Sales Per Salary Employee % 57 2 1999 In Sales Per Hourly Employee se rea Inc % 24 2 e as cre 2000 GE Power Systems 2001 1999 Year 2000 Year Productivity . . . Any Way You Look at It 10/07/ GE Company Proprietary 2001
    28. 28. Greenville Product Lines GE Power Systems • Heavy Duty Gas Turbines • 6 Models • 7EA, 7FA+e, 9FA+e, 7FB, 7H, 9H • 85 - 255 MW (Simple Cycle) • 7/9H = 400/480 MW (Combined Cycle) • Component Kits - BA’s • Rotors and Hot Gas Path Parts • Spare Parts 10/07/ rev 1
    29. 29. Environmental Health & Safety GE Power Systems • • • • • • • Employee Involvement Improvement Root Cause Analysis Process Partnership with SC OSHA - VPP in 2000 Injury/Illness rate < 50% National Average 100% Environmental Compliance Recycling Programs EHS Training 10/07/ P age 7 Committed to a Safe Environment GE Company Proprietary GE Company Proprietary
    30. 30. Community Service GE Power Systems • The Peace Center • • • • • United Way Hands-On-Greenville March of Dimes Junior Achievement Tanglewood Middle School Mentoring • • Habitat for Humanity ELFUN Society GE . . . Helping GE Company the World a Better Place Make Proprietary 10/07/ GE Company Proprietary
    31. 31. GE Power Systems H Advanced Technology Integrated Combined-Cycle System 10/07/ GE Company Proprietary
    32. 32. “H” Technology System Highlights GE Power Systems S107H S109H Efficiency (%) 60 60 Output (MW) 400 480 NOx 9 <25 Higher Firing Temperature Steam Cooled Stage 1 and 2 Buckets and Nozzles Steam Cooled Stage 1 Nozzle Increased Efficiency Higher Power Density Low NOx Capability H: First Gas Turbine Combined-Cycle Technology New and Innovative Steam Cooling Technology Capable of Performance and Low NOx Key to Superior 60% Thermal Efficiency 10/07/ GE Company Proprietary
    33. 33. Technology Advancement: Steam Cooling Advanced Open Loop Air Cooled Nozzle “H” Technology Closed - Loop Steam Cooled Nozzle Air Out Air Out Air In Air In Nozzle ∆ T ~ 280 °F 10/07/ GE Power Systems Steam In Out In Steam Out Nozzle ∆ T ~ 80 °F Increased Firing Temperature ~200 °F With Same Combustion Temperature (NOx) GE Company Proprietary
    34. 34. STAG 109H and 107H Combined Cycle System Diagram GE Power Systems Exhaust to Stack HRSG HP System Hot Reheat System Cold Reheat System LP Steam Comb T C HP IP/LP Air 10/07/ Gas Turbine Steam Turbine GE Company Proprietary Generator
    35. 35. Single Shaft – Smaller Footprint 2 x S207FA = 1000 MW GE Power Systems 2 x S107H = 800 MW H Technology: 45% > Power Density vs. FA 10/07/ GE Company Proprietary
    36. 36. 9H System Launch Site GE Power Systems Port Talbot 9H Gas Turbine being transported Baglan Bay Baglan Bay Power Station • 109H Rating: 480MW • Launch Site: Baglan Bay, Port Talbot, Wales, UK Schedule 1999 April S14.3 Approved July S36 Approved Oct/Nov FSNL-2 June Feb Site Survey Begin ReAnalysis Engineering Complete 10/07/ 2000 May-July Permits Oct Aug Start Site Mobilization Piling 2001 Dec GT, Gen Ship Jan ST Ship Start Up THIS MONTH GE Company Proprietary 2002 Oct Begin Characterization Testing 2003 Mar Complete Characterization Testing June Commercial Operation
    37. 37. 7H Gas Turbine in Test Stand GE Power Systems  400 MW, 60% Efficiency  FSNL Test  Pre-Shipment (FSNL-2) Test 10/07/ New Showcase Site for “7H” Technology Being Identified GE Company Proprietary 2/00 4Q02
    38. 38. H SUMMARY GE Power Systems • Revolutionary Solution to Meet Customer Needs – Steam Cooled Gas Turbine Allows Higher Efficiency and Power Density without Increased NOx • Product Based on GEPS / GEAE Experience and Proven Technology • Gas Turbine Combines FA Proven Features with H Technology Improvements • Leverages GE’s Single Shaft STAG Experience • Most Comprehensively Tested Industrial Gas Turbine • Controlled Introduction Strategy – Commercial Offerings Following Launch projects 10/07/ H : The New Generation of High Efficiency Combined-Cycle Technology GE Company Proprietary
    39. 39. GE Power Systems THANK YOU