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Cologne, Germany | 3-5, June 2014
Power-GEN Europe
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FlexEfficiency*50 Combined Cycle Power Plant A new standard of high efficiency and operational flexibility
Trevor Bailey
Cologne, Germany | 3-5, June 2014
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Overview
• Understanding our customers’ challenges • Integrated power plant development • System-based value creation • Major equipment integration • The FlexEfficiency*50 power plant • Summary
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Industry dynamics
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HDGT installed base to grow 50% next decade High efficiency projects leading the way
0
100
200
300
400
500
GE OEM A OEM B OEM C OEM D
25%
35%
40%
Tech Class3
B/E
F
High Eff.
Installed Base (GW) 1
Sources: 1. 2012 McCoy Power Reports cumulative HDGT >35 MW orders in GW for GE and select competitors 2. GE Finance and earnings reports from select competitor websites & annual reports 3. GE PGP Marketing Forecast of Heavy Duty Gas Turbine Orders next decade
Today Next Decade
• GE technology… 50% of IB (1000 GW) • More than half F-technology
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Changing world dynamics
Fuel price volatility Resource scarcity/
remote recovery efforts Reducing CO2 emissions
Energy efficiencies Energy policies Technology
advancements
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Power Plant development
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Plant product management philosophy
Plant System-based Structure (SBS)
Engi
neer
ing
Dis
cipl
ines
• Understanding the complete offering
• Common system-based structure
• Robust DoR models for ITO & OTR
• Align NPI to Plant product requirements
• Leverage constructability and modularity
Drives 3 dimensions Of plant configuration
Civil Engineering
Mechanical Engineering
Electrical Engineering
Environment Engineering
Controls Engineering
Requirements & Constraints
Function Physical Implementation
Understanding the Plant Systems to configure the Plant
TC BC HR EC PI
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Systems-based methodology guides configurations Plant configuration requirements
Plant configuration decisions 1. Modularization of GT enclosure 2. Use of plant fieldbus controls 3. Plant layout 4. Steam turbine side exhaust 5. Use of a clutch in single shaft 6. Generator position 7. Simplification of aux systems
1. Plant cost • Enhance equipt packaging • Height of the building • Type/height of foundation • Reduce aux steam need
2. Ease/speed of installation • Dense plant layout • Separation of work • Parallel installation
3. Operability and Maintainability • Fast start up capability • Minimal cranes sizes • Outage laydown space
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Re-engineering of GT enclosures and accessories
Plant configuration decision example Modularize GT enclosure and accessories
*7HA.01 compared to 7F.03 **piping between GE supplied equipment
Plant requirements fulfilled • Plant cost • Ease of installation • Speed of installation • Operability • Maintainability
Key value created • Reduced installation*: pre-wired, piped,
shipped assembled … 10k less man-hours • Less connections/welds*: field installed
valves – 451; field welds 525238 • Common interfaces: less field routed pipe,
interconnecting piping provided** • Maintainability built in: roof access, space
to drop combust cans, crane in module
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Plant configuration decision example Deploying digital fieldbus technology across the plant
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Simplified device couplers instead of junction boxes
Plant requirements fulfilled • Plant cost • Ease of installation • Speed of installation • Operability • Maintainability
Key value created • Reduction in startup and commissioning
time*: pre-configured devices and skids • Less installation cost*: 10,500 man-hours
less than I/O • Less wires and terminations: i.e., MOV
wires 800120; terminations 3,200130 • Enhanced trouble shooting capability:
smart digital devices identify a fault source *FFB compared to traditional I/O MOV – Motor Operated Valve
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Plant configuration decision example Plant layout for ease of construction, operations and maintenance
Mechanical work area
Electrical work area
Shaft line work area
1 x 9HA plant layout with separate work areas
Plant requirements fulfilled • Plant cost • Ease of installation • Speed of installation • Operability • Maintainability
Key value created • Layout capable of fast installation: 24
months NTP to COD • Separate work areas for construction:
parallel work with specific tasks • Turbine building through road: for
construction and 34 day major plant outage • Lower building cost: 5m lower* using pier
foundation and side inlet/ST exhaust *FE50 compared to 109F block 3 plant
9HA FlexEfficiency*50 Plant
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Key components 9HA gas turbine
World’s largest, most efficient gas turbine
Integrated approach
D650 steam turbine >40% shaft efficiency SS: 3 casing, lateral exhaust MS: Opposed-flow HP/IP
Plant configuration Smaller footprint, improved serviceability
W86 generator Reduced site assembly, enhanced serviceability
Mark Vie* ICS Plant controls Digital architecture, performance seeking algorithms
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Enhanced user interface Industry standard Enables faster assessment and
trouble shooting • Simple and intuitive • Actionable information • Easy to use • Quickly recognize items
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1x1 9HA FlexEfficiency*50 Power Plant • 600-700 MW, 50 Hz … 61%+ base load efficiency
• Start-up to full load <30 minutes
• Ramp-rate >60 MW/minute
• Plant turn-down to 50% load
• A new standard in efficiency AND flexibility
a product of
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Summary
Understanding the needs of the plant owner is critical
Develop the plant using Systems Based approach to value creation
Integrating the equipment in the
plant is key to competitiveness
17
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Integrated approach