GE Oil & Gas

MS5002E
A state-of-the-art heavy duty Gas Turbine

MS5002E Gas Turbine

SRL

C e nt r i fu g a l Co mp resso r

The MS5002E is the latest addition to the GE Oil & Gas family of gas turbines. This machine was developed in response to customer demand for a gas turbine in the 32 MW range with high efciency, availability and reliability, and low environmental impact.In order to guarantee high reliability and availability, the MS5002E has a conservative ring temperature with respect to the state-of-the-art. High efciency was achieved through the use of advanced design tools to optimize airfoils, clearances, leakages and the distribution of cooling ows. The MS5002E offers NOx emission levels down to 15 ppm through the use of a dry low emission combustion system derived from the GE DLN2 combustion technology. The design of the MS5002E was validated through an extensive test program that included a full scale test of the axial compressor, full scale rotordynamic testing, and full testing of the gas turbine system in both mechanical and generator drive congurations.

Compressor
The compressor is an 11-stage, high pressure ratio (17:1), axial ow design scaled-up directly from the GE10 gas turbine. The GE 10 eet list contains over 80 installed units and over 700,000 operating hours. During this time, the axial compressor has demonstrated its robustness and high performance. At the nominal operating speed of 7455 rpm, the airow is 101 Kg/ sec. The inlet guide vanes (IGV) and the rst and second stage stator blades have electrically actuated variable vanes. There are two bleed ports located along the ow-path: the 4th stage bleed is used for LP turbine wheel cooling and bearing sealing, and the 7th stage bleed is used for cooling and for surge control during start-up/shut-down. As in the GE10, the compressor rotor has a forward stub shaft, six discs and ve spacers, and an aft stub shaft, all locked together with 26 tie bolts. The compressor casings

are horizontally split for on-site maintenance. The air inlet casing supports Bearing #1, a combined tilting-pad journal and thrust bearing. The casing materials are cast iron for the inlet case, nodular cast iron for the intermediate case, and cast steel for the compressor discharge case.

Combustion system
The combustion system is a multican, reverse ow type, with six cans mounted on the compressor discharge case. It is derived from the GE DLN2 combustor design installed on F Class machines with an installed eet of over 700 units and more than 11,000,000 operating hours. The combustor architecture and materials are the same as for F Class machines (e.g., 6FA, 7FA, 9FA) but the ring temperature of the MS5002E was intentionally kept 100C lower to maximize parts life and maintenance intervals. Current operation is with gaseous

fuel but features are built in for liquid fuel capability. There are fuel nozzles in each combustion can. The fuel nozzles contain a premixing tube where fuel gas and air mix together before the primary burning zone, and a central body with a diffusion fuel gas circuit. The combustor operates in diffusion mode at low loads (less than 50%), and in premixed mode at higher loads with a 15 ppm NOx level. The fuel gas delivery system is provided with multiple gas control valves to distribute the fuel to the different gas circuits. An accurate split is maintained during premix operation to ensure both low emissions and low combustion dynamics. Field measurements on the rst installed unit reported emissions below 15 ppm NOx, and single digit (9 ppm NOx) was even recorded at partial load. Measured data (not for guarantee) are shown in the attached graph, and are encouraging for the ultimate capabilities of the MS5002E combustion system.

Combustors and emission results

20 18 16 14 NOx ppmvd 12 10 8 6 4 2 0
NOX15 november 07 NOX may 08 NOX15 february 10 NOX15 november 10

15 ppm

18

20

22

24

26

28

30

32

Load (MW)

PERFORMANCE
(@ ISO conditions)

MS5002E
Generator Drive 31100 kWe 35.0 17:1 10285 15 101 510 3000/3600 (both geared) Mechanical Drive 32000 kW 36.0 17:1 10000 15 101 510 5714 Combustor

Output SC Efciency (%) Pressure Ratio Heat Rate (kJ/kWh) NOx (ppm) Exh. Gas Flow (kg/s) Exh. Gas Temp. (C) Load Rated Speed (rpm)

HP turbine
The axial ow, two-stage reaction type HP turbine was designed to deliver high efciency over a broad power range. It consists of two turbine wheels, rst and second stage turbine nozzle assemblies, and turbine casings. Both stages of HPT nozzles are air cooled by compressor discharge air owing through each vane. Both stages of HPT buckets are cooled by compressor air owing through the dovetail and shanks into the buckets.

LP turbine
The power turbine uses the same general arrangement, materials and major components found on the PGT25+ whose installed eet consists of over 160 units and more than 2.5 million operating hours. The ow-path prole and airfoils were redesigned to allow 20% higher airow than the PGT25+.

Auxiliaries
The MS5002E package design is similar to that used in other mature

GE Oil & Gas gas turbines. As with the MS5002D, two separate structural steel frames make up the base supports of the gas turbine (one for the engine and one for the auxiliaries). In addition, a new design was recently developed to combine the two base plates into a single one. This solution reduces the installation time and the overall footprint (reduction in length of 3.4 meters) and will reduce the overall weight (reduction of 17tons). The gas turbine is mounted on its base plate by means of two forward supports, (exible in the axial direction), and two rear support legs. The engine base plate has approximately the same footprint as that of the MS5002D and contains both inlet and exhaust plenums. These plenums are suitable for both vertical and lateral orientation. The auxiliary base plate contains the lube oil system and reservoir, starting system with rotor turning device, and the fuel gas skid. This modular design permits different installation congurations for optimization of the plant layout to meet customer requirements. The MS5002E is equipped with a Speedtronic Mark VIe control system currently used on all GE gas turbine models. The

control system ia available both in simplex or triple modular redundant congurations.

Maintainability
The MS5002E was designed for maintainability with special consideration given to: Planned maintenance Handling and lifting of gas turbine components and main auxiliaries Special maintenance tools Location of boroscope ports Enclosure access doors and openings The horizontally split gas generator casings and the removable enclosure roof allow on-site maintenance. The power turbine is mounted on a special frame that permits it to be moved axially on the base plate. The module can be either disassembled directly on the base, or can be removed for off-base maintenance. Combustors can be disassembled without removal of the compressor discharge case, and bearings 1, 3 and 4 are easily accessible for inspection. The latest version of the package is now available with provisions for modular replacement embedded in the design. With this option, the engine can be dismantled, lifted onto temporary rails alongside the skid, slid away and replaced with another engine. This reduces the time for a Major Inspection from 18 days to just 3 days. Once removed, the engine can be reconditioned off-line and reserved as a spare.

HP turbine

New Package Single lift for MS5002E Dimensions and weights

13.6 m length 4 m width 4.05 m height 93 tons total weight LP turbine Modular replacement of a MS5002E engine

Testing and validation

Mechanical drive test Extensive testing and validation of the MS5002E was previously carried out by GE Oil & Gas in its facilities in Massa (Italy) including a complete prototype test and validation of the overall system (engine and auxiliaries). The test plan covered all critical operating phases (pre-start, crank, idle, diffusion full load, premixed full load, DLN tuning, LP turbine mapping, etc.) to cover all aspects necessary for validation of the design. Generator drive test Following the rst test campaign aimed at validating the machine under demanding mechanical drive requirements, a second campaign was conducted at the GE Oil & Gas facility in Massa (Italy), to prove the machine capabilities in power generation applications. The test stand arrangement included an MS5002E coupled with a 40 MW

electric generator through a speed reduction gearbox. The electrical power output was absorbed by a resistor bank. Twenty-four successful full load rejections, twenty-nine successful partial load rejections, and thirty one successful step load acceptances were conducted. The test results proved that the MS5002E is capable of stable operation at Full-Speed-No-Load, achieves full load rejections (32+ MW) with deceleration to amed idle without trips, and can exceed 5 MW load steps (up or down) from any initial load with frequency recovery in compliance with international standards. Final test runs were completed in January 2006 and proved the power generation capability of the MS5002E for both grid connected conditions and operation in an island mode. A post-test engine disassembly was also conducted and no machine integrity issues were found.

References
The rst commercial order for the MS5002E was awarded by the Yara Sluiskil Company for a fertilizer plant in The Netherlands. The unit was put into operation in October 2007, in a 24/7 power generation duty cycle, with full customer satisfaction. The YARA site results conrm the robustness of the design, with power and efciency above guarantees and emissions always below 15 ppm NOx (single digit at partial load). A special preventative maintenance inspection plan was initiated to extend the maintenance intervals leveraging the robustness of the design, and it is anticipated that the rst CI will be extended to 24k operating hours in the near future. In January 2011, the rst MS5002E in mechanical drive application completed commissioning in the Vavozhskaya Gazprom compression station (Russian Federation). Two other units are being installed and commissioning is expected in early 2011. The MS5002E was also selected to equip four stations in the Bovanenkovo-Ukhta pipeline in the Russian Arctic region, leveraging our partnership with REP Holding. The MS5002E was specially designed for the extreme conditions specied for this project, such as operating temperatures down to -50C and a shipping conguration designed specically for railway transportation. By 2012, all 16 units will be delivered. In July 2011, an additional MS5002E for power generation and steam production will be shipped to a fertilizer plant belonging to the Matix Group in the West Bengal region of India. Site operation is scheduled for early 2012.

Yara Sluiskil plant

Assembly of enclosure on gas turbine

Special shipping conguration for railway transportation

Vavozhskaya pipeline station

GE Oil &Gas Via Felice Matteucci, 2 50127 Florence - Italy T +39 055 423211 F +39 055 4232800 Nuovo Pignone S.p.A. www.ge.com/oilandgas

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