BHARATH HEAVY ELECTRICALS LIMITED
(Department of Communication & Public Relations)
ADVANCED CLASS GASS TURBINE ASSEMBLY & TESTING
FACILITIES INAUGURATED AT BHEL-HYD
Large Advanced Class Gas Turbine assembly and test facilities were inaugurated on
20th July, 2007 in Ramachandrapuram Unit by Sri Ashok K. Puri, Chairman &
Managing Director of BHEL. Sri K. Ravi Kumar, Director, Power also attended the
function. Sri G. V. Rami Reddy, Executive Director, Ramachandrapuram Unit has
received them and given a warm welcome.
Sri Ashok K Puri, CMD - BHEL has also inaugurated the Modernised Commercial Floor
in the Administrative building on 20th July, 2007.
( A. Panduranga Rao )
Sr. Manager / C&PR
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F- technology gas turbines are advance class machines involving high firing temperatures
with the capability of achieving higher plant thermal efficiencies and there by lowering fuel
costs and environmental emissions. The F technology machines are generally large gas
turbines to take advantage of the higher firing temperatures and hence offer high specific
power output. These highly efficient machines with their high specific power output provide
additional benefits in terms of generation of less amount of emissions like Nox and CO
per unit of power produced for the same exhaust concentrations. To incorporate the higher
firing temperatures, required changes have been carried out in the various key components
of the gas turbine engine to ensure that maintenance intervals are not adversely affected.
These involved changes in aerodynamic design of compressor, higher temperature
capable materials, more sophisticated hot gas path component cooling circuit etc. The
combined experience of GE F class gas turbines is more than 17.5 million fired hours.
The 9FA is a large gas turbine based on
the aerodynamic scale of the highly
successful 7FA gas turbine. It is of the
250 MW class gas turbine with it’s
efficiency greater than 37 % in simple
cycle and 56 % in combined cycle.It is
configured with a robust Dry low Nox
(DLN) 2+ combustor, which is ideally
suited for diverse fuels. The DLN 2+
combustor is an industry leader in
pollution prevention with capability of
achieving less than 25 ppm NOx levels.
The 9FA is a building block that can be
configured to meet site and power
requirements. It can be arranged in a
multishaft configuration where one or more gas turbines can be combined with a single steam
turbine to produce power blocks in multiples of approximately 390 MW.
Simple cycle Combined cycle
Output MW 255.6 390.8 786.9
Plant eff. % 36.9 56.7 57.1
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The 9FB is the latest evolutionary step
in GE's proven F series. The 9FB gas
turbine utilizes the materials
developed for the H system, leading to
further enhancement of firing
temperature over the 9FA by more
than 100 deg Fahrenheit resulting into
combined cycle efficiency ratings
improvement of better than 1 percent
and power output improvement of
more than 5 percent.
Simple cycle Combined cycle
Output MW 279.2 412.9 825.4
Plant eff % 37.85 58 58
After all the casings , bearing housing, exhaust
frame / diffuser etc are machined in the TCGT
shop, they are moved to the new assembly bay.
All the casings are built up into a vertical tube to
establish concentricity of the casings. Bearing
centerlines are established after the casings tube
is assembled horizontally and rested on base
frame support arrangement. Then the top
casings are opened to enable sequential
assembly of the internals and insertion of the
Rotor assembly. Assembly of the combustion
components and other auxiliary system piping
are taken up after the top casings are boxed up.
Fully assembled gas turbine is transported to
test bay for FSNL testing. On completion of test,
gas turbine is transported back to assembly bay
for dispatch preparation.
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Test Plant and Over-all Layout
Testing of the gas turbines at factory ensures
detection and addressing of “infant mortality”
failures. As is evident from the “bathtub”
reliability curve, failure rate of components/
devices is high during initial stages, plateaus
and then increases with aging. The test
program is intended to detect the potential
early failures at the factory itself rather than
having to deal with them during field operation.
Each gas turbine has to undergo following
cycle of test during the factory run test to
ensure the integrity of all related components Test Plant Control Room
1. Stand still tests
2. Initial cranking checks
3. Initial firing checks
Over all Mechanical Operation:
Detection and evaluation of leaks, rubs, vibration and cooling flows and any other
operation of mechanical nature that may need checking
Operation of Control System:
Control characteristics - smoothness of operation, stability, response time range
4. Performance tests
Performance test at 100% of rated turbine speed corrected to ISO conditions.
Evaluation of Compressor Air flow, Compressor Efficiency, Compressor Pressure ratio,
Monitoring of numerous other temperatures and pressure values.
5. Discrepancy Clearance
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6. Reliability runs
The reliability test consist of checking and/ or testing any system that experienced
problems during the previous test phases.
Ensure that the rework involved was adequate and the defect is cleared.
7. Customer Witness Tests.
8. Certification and Release from Test Bed
Frame-9FA/FB Test Facility
At the test facility assembled gas turbine is connected to test plant systems. The test facilities
includes following state of the art system to conduct the
FSNL test :
1. Inlet and Exhaust System : Inlet system consists of
instrumentation and flow measurement system to
accurately measure air flow up to 900 Kg/sec. The
assembled gas turbine is shifted to test plant by transport
trolley, lowered on the test bed by hydraulic jacks and
connected to test plant inlet and Exhaust Ducts.
2. Control & Protection System : all the control
instrumentation of the gas turbine is hooked up to state of
Mark VI GT Control
the art Speedtronic Mark VI control system. The sysem
advantage of Mark VI systems are : MARK-VI
Triple Modular Redundancy PANEL
Application specific control as fast as 100
High speed Peer to Peer Ethernet DC DISTRIBUTION
communication BOARD - DCDB
MOTOR CONTROL CENTRE
Can be configured for remote access.
On-line repair of any one channel in TMR.
Historic data storage and retrieval
The test plant Mark VI control system is
used for protection and control of gas System-2 in Data Acquisition System DAS server in
turbine as well as control of test plant Control Room
Motor Control Center & DC Distribution Data Acquisition
Board. System-1on Test Bed
3. Data Acqusition and Control System :
Besides the standard control
instrumentation required for normal
operation of the unit, the test facility is K type
3&4 wire Pt
Pressure Turbine Flow
equipped with additional instrumentation RTD
like pressure, temperature, flow
transmitters to measure and to validate the performance characteristics of the machine.
These instruments are hooked to test plant Data Acquisition System.
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4. Vibration Measurement System :Test plant is
equipped with monitoring systems like Bently 3500
series vibration monitoring and online vibration
analysis system ADRE 408SXP for validating the
rotor dynamics of the Gas turbine. The multi
channels system can record, correlate, analyze
dynamic and static data, vibration data & process
data. It is having full digital recording, data
streaming and simultaneous signal processing as
well as remote operation and viewing of results
5. Fire Protection System : The system generates
alarm , messaging on phone, audible siren in case
of fire and tripping of machine. It also consists of
CO2 release system in turbine load tunnel.
6. Fuel Forwarding System : The system consists
of two 120 KL High Speed Diesel tank,
pumping station for fuel transfer up to turbine
fuel system. The above configuration is
sufficient to run the machine at FSNL for more
than 12 hours. The system is equipped with
automatic pressure regulation, online level
monitoring, remote measurement of online fuel
parameter and generate alarm/trip command
interfaced with Mark-VI
7. Lube Oil System : The system consists of
Lube oil transfer system and Lube oil module
for lubrication and hydraulic control requirement to the turbine, Auto regulation of lube oil
pressure and temperature, Remote measurement of lube oil parameters like pressure,
temperature, flow and level through DAS and control of motor ON/OFF through Mark-VI,
Protection against high temperature, low pressure & low/high level interfaced to Mark VI for
generation of alarm or trip command to machine
8. Cooling Water System : Consists of 1000 m³/hr capacity cooling tower, two 500 m³/hr
capacity cooling water pumps with pump ON/OFF & Lead/Lag control interfaced with Mark VI
control, automatic flow regulation with the help of temperature control valve and remote water
parameter measurement through data acquisition system.
The data generated through the test is sufficient to detect, analyse and rectify the potential
failure at factory itself. The above data will be also available over factory LAN for Engineering
Gas turbine testing as performed by BHEL Testing Department is a methodical thorough Quality
Test of a high technology rotating machine. It is intended to demonstrate Design Soundness
as well as Manufacturing Completeness and Quality. All phases of the process have been well
thought/planned/executed. All these activities so far are the culmination of proven manufacturing
process that reflect the years of BHEL experience in the Heavy Duty GAS TURBINE business.
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