GE Gas Turbine User Manual
Gas Turbines
GE Energy
Oil & Gas
2 GE Energy
Gas Turbines
Contents
Introduction
GE5
GE10
MS5001
MS5002C-D
MS5002E
MS6001B/MS7001EA/MS9001E
PGT16
PGT25
PGT25+
LM6000
Main Components
Axial Compressor
First Stage Nozzles
Buckets and Wheels
Gas Turbine Operability
LNG Exploration and Production,
Floating Production Units
Pipeline
Refinery and Petrochemicals
Test Facilities
Service
Training
Gas Turbine Data Sheet
3
4
8
10
11
12
13
14
15
16
17
18
18
19
19
20
22
23
24
25
26
27
28
3 GE Energy
Gas Turbines
GE Energy manufactures a complete line of gas turbines for all major Oil & Gas
Industry applications. They are installed in natural gas plants, gas compression
stations, oil booster stations, petrochemical plants and power generation and
cogeneration plants worldwide. GE Energy Oil & Gas Business has long-standing
experience in manufacturing gas turbines dating back to 1961 when a
manufacturing agreement was established with General Electric (U.S.A.) to
complement the existing portfolio of products for the petroleum and petrochemical
industries (reciprocating and centrifugal compressors, gas engines, pumps, valves,
etc.). A proven combination of sound design and quality assurance techniques
places these gas turbines among the world’s most reliable. Basic models produced
by GE Energy cover the 5,000 to 124,000 kW power range. They can be provided in
simple or regenerative cycles for mechanical drive or generator drive applications.
Extensive research and development, advanced design procedures, modern
manufacturing technology and on-site experience are behind the success
achieved by GE Energy gas turbines.
4 GE Energy
Gas Turbines
GE5 Gas Turbines
COMPRESSOR
The GE5 compressor benefits from several decades of
compressor design evolution focused on achieving
higher efficiency. The new compressor is scaled from
the similar GE10 unit. It is a high performance, axial flow
design derived from GE Aircraft Engine technology. GE
Energy, utilizing GE Aircraft Engine expertise, has greatly
improved overall compressor performance without
sacrificing reliability or mechanical integrity.
The 11-stage compressor produces a pressure ratio of
14 8:1. The first three stages of stator blades are
adjustable to optimize efficiency by maximizing exhaust
gas temperature at part load operation. Compressor
blades are assembled onto a solid forged rotor while
stator blades are mounted onto ductile cast iron
casings.
TURBINE
The HP turbine itself is a compact, high efficiency
design with two stages in the single shaft version and
three stages in the twin shaft model (2 in the LPT
Turbine). The advanced design methodology utilized by
GE Energy resulted in a high performance machine
with significantly fewer parts. In addition, state-of-theart cooling techniques permitted the use of well proven
materials.
The GE5 uses an enhanced nozzle and bucket design
similar to those used in aircraft engines. Cooling air is
provided to the first stage nozzles and buckets to
enable higher firing temperatures and enhanced
efficiency.
The LP turbine of the twin shaft version has two stages
The new GE5 is a compact, state-of-the-art, 6 MW class industrial gas turbine. The unit was
developed in two configurations: a cold-end drive single shaft for power generation and a hotend drive twin shaft for mechanical drive applications. Maximum commonality has been
maintained between the single and twin shaft models. Both units share a common gas
generator, with operating and maintenance benefits in installations where mixed operation is
required. The twin shaft engine is obtained by simply removing the second stage turbine from
the single shaft unit and adding a two-stage power turbine.
The unit is an evolution of the existing PGT5 which builds on the experience of the successful GE10
model. The merging of proven GE Aircraft Engines and GE Energy - Oil & Gas technology coupled
with the benefits of GE’s Six Sigma Total Quality Methodology have resulted in a rugged machine
with high efficiency and reliability, and low operating and maintenance cost.
The high efficiency of the machine coupled with low emissions make the GE5 a leader in its class
for most applications.
While the single shaft version is particularly suitable for power generation and cogeneration due
to the high exhaust temperature, the twin shaft version, with wide operating speed range, is
designed to be a reliable and efficient mechanical drive for compressors and pumps.
5 GE Energy
Gas Turbines
GE5-1 Gas Turbine
and has been designed exploiting the experience the
company has gained over the past 20 years with the
PGT25, PGT10, PGT16 and more recently with the
PGT25+ (High Speed Power Turbine). The design speed of
the GE5-2 low pressure turbine is 12,500 rpm, with a
capability range from 50% to 105%, which is ideal for
direct coupling of GE Energy centrifugal compressors in
the 6 MW power range.
COMBUSTOR
The GE5 uses an annular combustor architecture, to
achieve the maximum efficiency while maintaining the
highest reliability standards. The unit is configured with
a DLE combustion system that reduces the NOx and CO
emission levels. It consists of a compact annular
combustor in Hastelloy X with 18 fuel nozzles. Each fuel
nozzle includes a double counter-rotating swirler to
optimize fuel mixing and flame stability for extra clean
combustion.
This combustion system is designed for operation on
natural gas. One fixed, high-energy spark ignitor is used
to achieve simple and reliable ignition.
6 GE Energy
Gas Turbines
GE5 Gas Turbines
PACKAGE
The gas turbine packages were designed with an
emphasis on standardization, and optimization of
factory and field assembly operations. The result is a
standard package capable of satisfying the needs of a
typical user for low installation and maintenance costs.
The package is also designed and manufactured as a
modular system. Both the single and twin shaft gas
turbines are normally supplied as completely enclosed,
on-base soundproof packages of very compact
dimensions with standard noise attenuation levels of 85
dB(A) at 1 m. The Starting System, Lube Oil System and
Fuel System are fully integrated on the base plate.
In the single shaft configuration, the base plate also
supports the load gear; the off-base equipment is
limited to the lube oil cooler and the generator. The
entire GE5-1 package is compact, with a footprint of
only 5810 mm (L) x 2500 mm (W) providing the user with
the flexibility to locate the system indoors or near preexisting facilities. The inlet filtration module and inlet
duct are designed to be perfectly integrated with the
enclosure and, in order to optimize the footprint and
transportation, are supported by the enclosure itself.
For the twin shaft, the design guideline has been the
flexibility to satisfy a broad spectrum of customer plant
needs. As required by the Oil & Gas Industry, the
standard enclosure was designed to be equipped with
different filtration systems (conventional/self cleaning),
different inlet/exhaust duct arrangements and noise
levels and always allowing high accessibility and
maintainability.
Both the single and twin shaft packages are provided
with wide access doors conveniently located around the
enclosure for easy access to the engine assembly and
auxiliary components.
7 GE Energy
Gas Turbines
MAINTENANCE PHILOSOPHY
A fundamental philosophy of the new GE5 gas turbine
is simplicity of design, layout and procedures. This
affords the GE5 a position of market leadership in cost
and availability through innovative programs for
service and sparing, and through package assembly
and disassembly flexibility. Drawing on GE’s undisputed
leadership in the design and manufacture of both
aero-derivative and heavy-duty machines, the GE5
represents a unique marriage of the best of both types
of engines.
This provides customers with the benefit of a variety of
cost-effective service programs (e.g., condition-based
maintenance, site-based or exchange engine programs)
and the ability to tailor the service offering to best suite
the customer’s specific applications.
SOME KEY POINTS:
Annual borescope inspections are the basis of the
condition based maintenance program.
The inspection of the hot parts is carried out
approximately every two years. Major overhaul of the
gas turbine is required at around 50,000 fired hours,
and can be completed on site, or in a shop; effects of
downtime can be minimized through the use of an
exchange engine.
GE5-2 Gas Turbine
8 GE Energy
Gas Turbines
The GE10 is a 12 MW range heavy-duty gas turbine available in both single shaft and two shaft
versions. It is the evolution of the field-proven PGT10A and incorporates the latest in
aerodynamic design in a compact and versatile package arrangement. The design of the GE10
has been highly refined based on the extensive experience gained operating in all types of
environments. There are over one hundred units running under conditions ranging from the cold
of Alaska and Siberia to the heat of the desert and the humidity of the tropics.
Its efficiency and operational flexibility make the GE10 a cost-effective choice for all applications.
The gas generator consists of an 11 stage, high efficiency, axial-flow compressor and a single
combustion chamber capable of burning a great variety of fuels. Maximum commonality has been
maintained between the single and twin shaft models. Both units use the same gas generator. The
two shaft engine is obtained by simply removing the third stage turbine from the single shaft unit
and adding a two-stage low pressure power turbine. This feature is particularly beneficial in
reducing operating and maintenance costs in installations where mixed operation is required.
GE10 Gas Turbines
GE10-1 Gas Turbine
COMPRESSOR
The compressor is a high performance eleven stage
axial flow design with a 15.5:1 pressure ratio
operating under transonic flow conditions, derived
from GE Aircraft Engine aero-derivative technology.
The first three rows of stator blades are variable to
optimize cycle efficiency over a wide range of loads.
The gas generator is joined to the base plate at the
load flange location. This configuration avoids load
flange movement during all operating conditions
(start-up, warm-up, full speed/full load) and during
thermal transients.
TURBINE
The power turbine is available in two configurations: a
single shaft version primarily for power generation; and
a two shaft version for mechanical drive applications.
Generator Drive — Single Shaft Version.
The GE10-1 is a single shaft heavy duty gas turbine
designed primarili for generator drive applications.
The turbine section is composed of three reaction
stages. The first two stages use the proven design of
the previous PGT10 HP turbine model with cooling
provided by air bled from the axial compressor.
The second and third stages have interlocked shrouds to
limit tip leakage and blade vibration. At partial load, inlet
variable guide vanes permit optimization of performance
with no appreciable change from simple cycle full load
efficiency.
The GE10 is a compact turbogenerator optimized for
simple cycle, combined cycle and cogeneration plants
(e.g., power shaft on cold side; axial discharge of hot
gases) and suitable for utilization even where space is
limited.
9 GE Energy
Gas Turbines
Mechanical Drive — Two Shaft Version.
The GE10-2 is the two shaft version of the GE10
intended for mechanical drive applications. The turbine
consists of four reaction stages. The first two stages or
High Pressure Turbine which are used to drive the axial
compressor are common with the GE10-1 model. The low
pressure shaft is a double stage, high-energy turbine with
variable first stage nozzles which provide maximum
flexibility for mechanical drive applications. These third and
forth stages which make up the Low Pressure Turbine are
coupled to the power shaft driving the load. They are
cooled by air bled from the axial compressor.
COMBUSTOR
The combustion system consists of a single, slot-cooled
combustion chamber assembly that permits quick and
easy maintenance of the hot gas path. This combustion
chamber is able to burn a wide range of fuels including
liquid distillates, residuals and all gaseous fuels including
low BTU gas with system modifications.
The GE10 combustion system is available in both
conventional and DLE configurations. The DLE (dry low
emissions) system is a simple, field-proven design that
guarantees operation at 25 ppmv NOx (burning Natural
Gas). The GE10 can also utilize steam and water
injection for NOx reduction and power augmentation.
Further reduction of emission levels is a constant
objective of our continuing combustion development
and test programs.
AUXILIARIES
The integrated lubrication system (including oil tank)
that feeds the gas turbine, the speed reduction gear and
the electric generator is located on the turbine base
plate. The main lube oil pump is mechanically driven by
the gearbox. An AC electric motor-driven pump
guarantees lubrication during normal operation while a
DC electric motor-driven pump is provided for
emergency backup. In the standardized package
configuration the oil is cooled by an air cooler. A water
cooler can be provided upon customer request.
The thrust and journal bearings are of the tilting pad type.
The starting system consists of a V.F.D. motor drive for the
single shaft version.
The twin shaft can be equipped with a torque converter
plus electric motor or starting expansion turbine.
The GE10 control system has been implemented to
assure a high degree of integration and standardization
between the engine and the turbine generator package.
Programmable modules guarantee easy
implementation of any control and protection scheme
to tailor the control system to the application and
customer needs.
PACKAGE
The package designed for power generation
applications is optimized to minimize plant dimensions
and to reduce maintenance cost and time. In the
standard configuration, the speed reduction gear is
mounted on the gas turbine base plate. The auxiliaries
are installed on a separate base plate permanently
joined to that of the gas turbine base plate to form a
single lift on which the sound-insulated enclosure is
mounted.
The electric generator is installed on a concrete
foundation to limit the shipping dimensions. The overall
length of the genset is about 13 m.
The other modules completing the system are the
oil/air exchangers, the air intake filter chamber, the
suction duct (vertical suction) and the exhaust system
(axial exhaust).
The enclosure has a sound pressure level lower than 85
dBA at 1 m. This acoustic design meets ISO NR 50 limits
at 100 m.
10 GE Energy
Gas Turbines
MS5001 Gas Turbines
MS5001 Gas Turbine
The MS5001 single shaft turbine is a compact heavy-duty prime mover designed for long life and ease
of operation and maintenance. The three main features of its simple design are:
- 17-stage, axial compressor
- Combustion system with 10 chambers capable of burning a wide range of fuels including natural
gas, light and heavy distillates, and crude and residual oil. A DLN System is also available.
- Two-stage turbine with high energy stage design. The first-stage nozzles are cooled by the axial
compressor discharge air.
The MS5001 Gas Turbine is the ideal solution for power generation where low maintenance, reliability
and economy of fuel utilization are required. Low operating and investment costs make the MS5001
package power plant an economically attractive system for load generation. The MS5001 is also
ideally suited for cogeneration achieving a very high fuel utilization index and considerable fuel
savings. Typical applications are industrial plants for cogeneration of power and process steam or
district heating systems.
As a consequence of the extremely favorable operating, maintenance and economic
characteristics of the MS5001 it has been very well accepted in the industry and there are more
than 2500 units in operation all over the world.
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