The PGT25+G4 gas turbine, latest in GE Infrastructure Oil&Gas PGT25 two-shaft aeroderivative family, is a 34 MW-class gas turbine for mechanical drive and power generation applications and maintains the same efficiency and availability of the previous PGT25+. The PGT25+G4 was validated through an extensive test program, which included some key test-rigs such as the full-scale LM2500+G4 Gas Generator test and other component tests, in advance of the First Engine to Test (FETT). The FETT included an equivalent-to-production configuration package (gas turbine, auxiliaries and control system), ran in a dedicated area in GE Oil&Gas Test Facilities to validate the machine for both mechanical drive and power generation applications. All critical-to-quality parameters of the HSPT (High Speed Power Turbine) were investigated, such as turbine gas path components temperatures and stresses, PT performances and PT operability when coupled with the LM2500+G4 Gas Generator. First production unit is currently in operation at Alliance Pipeline Canada Windfall 1 Compression Station. This paper describes the gas turbine main features, how the test program was built and discusses FETT results. Moreover, gas turbine field operation experience and lessons learned are presented.
The NovaLT™16 gas turbine recently developed in Baker Hughes, a GE company (BHGE), is part of a larger class of gas turbines (LT class) aiming at covering a wide space in the small power range segment and at introducing in the market a state of the art technology engine for what concerns performance, emissions, operability, durability and maintainability. The main purpose of this paper is to describe the entire validation campaign that was performed at BHGE facilities. This campaign can be divided into 3 different phases. The first phase focused on measuring engine performance in a new, clean and unaltered configuration. The second phase focused on emissions, vibration, thermal distribution, auxiliary system performances and the like, in order to validate the design assumption and calculation results across the full operational range. In this phase, more than 2000 sensors were installed across the entire engine, covering all modules, and all functional tests were performed (inside and outside of design space) to guarantee reliable engine behavior. At the end of this test phase, a full engine teardown was performed to allow a detailed parts inspection that confirmed the achievement of the design intent. The standard maintenance plan of the engine requires 35Kh continuous running. Therefore, the third part of the test aimed at validating engine durability with a full endurance test that allowed the identification and correction of any possible remaining operation problem. In this phase, the engine was still equipped with more than 1000 sensors, and was operated continuously following a well-defined operating profile in order to simulate both mechanical drive and power generation modes. This campaign successfully allowed to fine tune several engine control logic details, to monitor emissions behavior across a wide range of ambient temperature and load condition (the test spans from hot to cold day), to analyze trends of standard engine parameters and special instrumentation and, through planned borescope inspection, to evaluate individual component status versus selected operating profile. Data reported in this paper represent a summary of all the data acquired and post processing results, and illustrate how an endurance test can help tuning machine performance predictions in a wide operating range.
The combination of the continuously growing demand of energy in the world, the depletion of oil and its sharp price increase, as well as the urgent need for cleaner and more efficient fuels have boosted the global trade of liquefied natural gas (LNG). Nowadays, there is an increasing interest on the design philosophy of the LNG receiving terminals, due to the fact that the existing technologies either use seawater as heating source or burn part of the fuel for regasifying LNG, thus destroying the cryogenic energy of LNG and causing air pollution or harm to marine life. This investigation addresses the task of developing novel systems able to simultaneously regasify LNG and generate electric power in the most efficient and environmentally friendly way.Existing and proposed technologies for integrated LNG regasification and power generation were identified and simple, efficient, safe and compact alternatives were selected for further analysis. A baseline scenario for integrated LNG regasification and power generation was established and simulated, consisting of a cascaded Brayton configuration with a typical small gas turbine as topping cycle and a simple closed Brayton cycle as bottoming cycle. Various novel configurations were created, modeled and compared to the baseline scenario in terms of LNG regasification rate, efficiency and power output. The novel configurations include closed Rankine and Brayton cycles for the bottoming cycle, systems for power augmentation in the gas turbine and combinations of options. A study case with a simple and compact design was selected, preliminarily designed and analyzed according to characteristics and costs provided by suppliers. The performance, costs and design challenges of the study case were then compared to the baseline case. The results show that the study case causes lower investment costs and a smaller footprint of the plant, at the same time offering a simple design solution though with substantially lower efficiencies.
In gas turbines, High Cycle Fatigue (HCF) bucket failures are mainly prevented by avoiding resonance frequencies in the operative range. Due to the high number of stimuli present, avoiding potential resonance crossings is often not possible. In these cases, failures can be avoided by controlling vibratory stress levels in order not to exceed high cycle fatigue endurance limits. This paper describes the processes used in GE Infrastructure, Oil&Gas to design, develop and test a new high-pressure turbine bucket for a 32 MW-class industrial gas turbine for mechanical drive and power generation applications. Initial design phases, material selection, concurrent engineering efforts, bench testing characterization and final validation on FETT (First Engine to Test) are described. A particular focus is given to the analytical tools (i.e. Modal Cyclic Analysis) used in the design phase and the validation tests (i.e. Ping Test and Laser Doppler Vibration) including the development of a dedicated instrumentation technique, which allowed the unit not to be disassembled (High Temperature Strain Gauge Splicing).
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