© 2004 Nuovo Pignone S.p.A., all rights reserved;
any use or reproduction even if partial is prohibited without a specific written authorization.
CONTENTS
Introduction 1 GE5 2 GE10 4 MS5001-5002C-5002D-5002E 6 MS6001B-7001EA-9001E 8 PGT16/LM1600 9 PGT25/LM2500 - PGT25+/LM2500+ HSPT 10 LM6000 11 Main Components 12- Combustion System & Fuel Systems 16
- Lube Oil System 17
- Auxiliaries 18
- Controls 19
Regenerative Cycle 20
Pipeline Standard Units/Packages 21 Gas Water Injection & Gas Storage Units/ 22 Downstream Plants/Test Facilities
Six Sigma Quality Program 24 Research & Development 25
Global Services 26
Training 27
Some Installations 28
1
Gas
Turbines
GE Oil & Gas
manufactures
a complete line
of gas turbines for
all major Oil & Gas
Industr y applications.
They are installed in natural
gas plants, gas compression
stations, oil booster stations,
petro-chemical plants and power generation and
cogeneration plants worldwide. GE Oil & Gas has long-standing experience in
manufacturing gas turbines dating back to 1961 when a manufacturing
agree-ment was established with General Electric (U.S.A.) to compleagree-ment the existing
portfolio of products for the petroleum and petrochemical industries
(recipro-cating 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 Oil
& Gas 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
applica-tions. Extensive research and development, advanced design procedures,
mod-ern manufacturing technology and on-site experience are behind the success
achieved by GE Oil & Gas gas turbines.
2
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 hot-end 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 oper-ating 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 sin-gle shaft unit and adding a two-stage power turbine.
The unit is an evolution of the exist-ing PGT5 which builds on the expe-rience of the successful GE10 model. The merging of proven GE Aircraft Engines and GE Power Systems - 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. The robust design incorporates dual fuel capa-bility, a range of standard options, and quick and easy on-site mainte-nance.
While the single shaft version is par-ticularly suitable for power genera-tion and cogeneragenera-tion 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.
DESIGN PHILOSOPHY COMPRESSOR
The GE5 compressor benefits from sev-eral decades of compressor design evo-lution focused on achieving higher effi-ciency. 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 Oil & Gas Nuovo Pignone, utilizing GEAE expertise, has greatly improved overall compressor performance without sacrific-ing reliability or mechanical integrity. The 11-stage compressor produces a pressure ratio of 15:1. 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 reaction stages in the single shaft version and one reac-tion stage in the twin shaft. The advanced design methodology utilized by GE Oil & Gas resulted in a high performance machine with significantly fewer parts. In addition, state-of-the-art cooling tech-niques permitted the use of conventional materials.
The GE5 uses enhanced nozzle and buck-et materials similar to those used in air-craft 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 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 LM2500+ HSPT (High Speed Power Turbine). The design speed of the GE5 power turbine is 16,630 rpm, with a capability range from 50% to 105%, which is ideal for direct coupling of GE Oil & Gas centrifugal compressors in the 6 MW power range.
COMBUSTOR
The GE5 uses a design similar to proven aircraft engines, to achieve the maximum efficiency while maintaining the highest reliability standards. The standard unit is configured with a DLE combustion system
that reduces the NOx and CO emission lev-els. It consists of a compact annular com-bustor 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 or liquid fuel with the potential to switch from one fuel to the other at any load. One fixed, high-energy spark ignitor is used to achieve simple and reliable ignition.
PACKAGE
The gas turbine package was designed with an emphasis on standardization, and optimization of factory and field assembly
GAS TURBINES
GE5
3
locate the system indoors or near pre-existing facilities. The inlet filtration mod-ule and inlet duct are designed to be per-fectly 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 plant customer 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 operations. The result is a standard pack-age capable of satisfying the needs of a typical user for low installation and main-tenance 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 baseplate.
In the single shaft configuration, the baseplate also supports the load gear; the off-base equipment is limited to the lube oil cooler and the generator. The entire package is compact, with a footprint of only 5810 mm (L) x 2500 mm (W) providing the user with the flexibility to
are provided with wide access doors con-veniently located around the enclosure for easy access to the engine assembly and auxiliary components.
In both configurations the standard scope of supply also includes:
• Ventilation System • Oil Mist Separator • CO2Fire Fighting System
CONTROL SYSTEM
The control system consists of a turbine control panel, generator control panel, excitation panel and a terminal cabinet. For ease of installation or operational convenience these cabinets can be located in an existing control room. Microprocessor based controls are used. The control system is configured for fully automatic operation and has provisions for connection to a Remote Monitoring and Diagnostics System.
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 leader-ship in cost and availability through innovative programs for service and sparing, and through package assem-bly and disassemassem-bly 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 engine. This provides Customers with the ben-efit of a variety of cost-effective service programs (e.g., condition-based main-tenance, site-based or exchange engine programs) and the ability to tai-lor the service offering to best suite the customer’s specific applications.
SOME KEY POINTS:
Annual borescope inspections are the basis of the condition based mainte-nance program.
The inspection of the hot parts is car-ried 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 ina shop; effects of downtime can be min-imized through the use of an exchange engine.
GAS TURBINES
4
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 incorpo-rates 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 humid-ity of the tropics.
Its efficiency and operational flex-ibility make the GE10 a cost-effective choice for all applica-tions. The gas gererator consists of an 11 stage, high efficiency, axial-flow compressor and a sin-gle 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 pres-sure power turbine. This feature is particularly beneficial in reducing operating and maintenance costs in installations where mixed opera-tion is required.
COMPRESSOR
The compressor is a high perfor-mance 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 opti-mize cycle efficiency over a wide range of loads.
The gas generator is joined to the base plate at the load flange loca-tion. 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 primarliy for gen-erator drive applications.
The turbine section is composed of three reaction stages. The first two stages use the proven design of the pre-vious PGT10 HP turbine model with cooling provided by air bled from the axial compressor.
The second and third stages have inter-locked shrouds to limit tip leakage and blade vibration. At partial load, inlet vari-able 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 dis-charge of hot gases) and suitable for utilization even where space is limited.
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 noz-zles 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 dis-tillates, residuals and all gaseous fuels including low BTU gas with system mod-ifications.
The GE10 combustion system is avail-able in both conventional and DLE con-figurations. 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 injec-tion for NOx reducinjec-tion and power aug-mentation. Further reduction of emis-sion levels is a constant objective of our continuing combustion development and test programs.
GAS TURBINES
GE10
5
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 baseplate. The main lube oil pump is mechanically driven by the gearbox. An AC electric motor-driven pump guarantees lubrication during nor-mal 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 hydraulic motor driven by high pressure
oil supplied by an AC motor-driven pump. For black start-up a diesel engine-driven pump is available as an option.
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 guar-antee easy implementation of any con-trol and protection scheme to tailor the control system to the application and customer needs.
PACKAGE
The package designed for power gen-eration applications is optimized to minimize plant dimensions and to reduce maintenance cost and time. In the standardized configuration, the speed reduction gear is mounted on the gas turbine baseplate. The auxil-iaries are installed on a separate base-plate permanently joined to that of the gas turbine baseplate to form a single lift on which the sound-insulated enclo-sure is mounted.
The electric generator is installed on a concrete foundation to limit the ship-ping dimensions. The overall length of the Genset is about 13m.
The other modules completing the sys-tem are the oil/air exchangers, the air intake filter chamber, the suction duct (vertical suction) and the exhaust sys-tem (axial exhaust).
The enclosure has a sound pressure level lower than 85 dBA at 1 m. This acoustic design meets ISO NR 50 lim-its at 100 m.
GAS TURBINES
GE10
Axial compressor Combustion chamber pollution prevention DLN6
MS5001
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
cham-bers 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 ener-gy-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 invest-ment costs make the MS5001 pack-age power plant an economically attractive system for load genera-tion. 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 opera-tion all over the world.
- High pressure shaft consisting of a 16-stage (17 for MS5002D), axial-flow compressor and a single-stage, high-energy turbine. The first stage nozzles are air cooled and the second stage nozzles are of the variable angle type. - Low pressure shaft is a single stage,
high-energy turbine.
- Twelve combustion chambers are con-tained within a single wrapper. A wide range of gaseous and liquid fuels can be burned. A DLN Combustion System is also available.
- A centralized lube oil system supplies clean, cooled, pressurized oil to lubri-cate the gas turbine and the driven equipment including the oil required for any compressor seals.
As a consequence of the extremely favor-able operating, maintenance and econom-ic characteristeconom-ics of the MS5002 nearly 500 units (more than 300 manufactured by Nuovo Pignone) have been installed world-wide in all types of environments (arctic, desert, off-shore etc.) always demonstrating ease of operation and very high reliability and availability (99%).
MS5002C-D
The MS5002 is a gas turbine specifically designed for mechanical drive applica-tions such as gas boosting, gas injec-tion/reinjection, oil & gas pipelines, LNG plants and gas storage. It has a broad operating speed range to meet the operating requirements of the most common driven equipment (centrifugal compressors and pumps) as well as the ability to burn a large variety of gaseous and liquid fuels. The MS5002 gas turbine was introduced in the mar-ket in the 1970s and has been updated and up-rated over the years to meet the industry demand for increased output. Presently two versions are available: MS5002C
MS5002D
The MS 5002 two-shaft, heavy-duty gas turbine is designed for high operating efficiency over a wide range of speed and load. The simple design and extreme robustness of the MS5002 allow com-plete maintenance to be performed on site without the need for specialized tool-ing or service shop assistance. The main features of its design are:
Model series 5001 heavy-duty gas turbine
GAS TURBINES
MS
5001
5002C-D
5002E
7MS5002E
The MS5002E, the latest addition to the GE Oil & Gas family of gas turbines, is a 30MW-class machine designed for high efficiency, low environmental impact
and high reliability. The MS5002E will be avail-able in both single- and dual-shaft versions to cover power generation and mechanical drive applications.
This latest machine was developed in response to Customer demand for a machine in the 30 MW range with low fuel consumption, reduced emis-sions and high availability and reliability. In order to guarantee high reliability and availability the MS5002E has a conservative firing temperature with respect to the state-of-the-art. High efficiency was achieved through the use of Advanced design tools to optimize airfoils, clearances, leakages and the distribution of cooling flows.
The MS5002E offers NOx emission levels down to 25 ppm (intro) through the use of a dry-low emis-sion combustion system derived fronm the GE Power Systems DLN2 combustion technology. The design of the MS5002E was thoroughly validated through an extensive test pro-gram that included a full scale test of the axial compressor, full scale rotordynamic testing and full load testing of the gas tur-bine system.
The MS5002E single-and dual-shaft 30MW-class machine repre-sents a world-class engineering achieve-ment to provide Customers with a high efficiency, low emissions machine with outstanding reliability matched for Oil & Gas Industry applications.
GAS TURBINES
MS
5001
5002C-D
5002E
Model series 5002 heavy-duty gas turbineIntroductory Performance
• Output Shaft 30 MW • SC Efficiency 36,4% • LPT Shaft Speed 6100 rpm • Exhaust Temperature 523 °C • NOx Emission 25 ppmGAS TURBINES
MS
6001B
7001EA
9001E
6001B
7001EA
9001E
GAS TURBINES
MS
8MS6001B
The MS6001 is a single-shaft, heavy-duty gas turbine. The high efficiency axial compressor has 17-stages. The com-bustor has ten combustion chambers with individual fuel nozzles. The machine has a three-stage impulse turbine with air-cooled buckets ans stationary noz-zles on the first two stages to achieve higher firing temperatures and conse-quently higher efficiency without compro-mising hot section component life.
MS7001EA
The GE MS7001EA is a highly reliable, mid-sized packaged power plant devel-oped specifically for 60 Hz applica-tions. With design emphasis placed on energy efficiency, availability, perfor-mance and maintainability, the 7EA is a proven technology machine with more than 775 units of its class installed or on order worldwide as of December 1999. The simple, medium-sized design of the 7EA lends itself to flexibility in plant layout and easy, low cost addition of power augmentation when phased capacity expansion is needed. A predecessor of the 7FA, the 7EA is ideal for plants that require high efficiency along with shaft speed for direct coupling to the generator.
APPLICATIONS
The 7EA is fuel-flexible, and can operate on natural gas, liquefied natural gas (LNG), distillate and treated residual oil in a variety of applications including: - mechanical drive for large LNG
com-pressor trains
- simple cycle and combined cycle - base load and peaking power
genera-tion
- industrial and cogeneration
MS9001E
The MS9001 is a single-shaft, heavy-duty gas turbine developed for gener-ator drive service in the 50 Hertz mar-ket. Its efficiency is approx 33% in simple cycle mode and over 50% when operated as a combined cycle. The MS9001 is designed to burn a variety of liquid and gaseous fuels.
FEATURES:
- 17-stage compressor with stacked disk design.
- reverse flow combustion system with 14 combustion chambers, each with an individual nozzle
- 3-stage turbine with air-cooled, first and second-stage nozzles and buckets - three-bearing rotor supports
Other GE GAS TURB
INES
GAS TURBINES
PGT
16
/LM
1600
9
Aeroderivatives GAS TURBINES
Package
- Completely mounted on a single base plate
- The enclosure is integral with the baseplate providing maximum acces-sibility for maintenance of the gas turbine and auxiliaries
Emission Control
- Steam or water injection systems for NOx abatement
- Dry Low Emission (DLE) combustion system
LP cpmpressor, 7 stage HP com-pressor)
- Pressure ratio 20.1:1
Combustion
- Annular combustion chamber (18 fuel nozzles)
Turbine
- Twin Spool Gas Generator turbine (1 stage HP turbine, 1stage LP turbine) - Two stage Power turbine with
vari-able angle first stage nozzles
PGT16/LM1600
The PGT16/LM1600 gas turbine is composed of the twin spool GE Aeroderivative LM1600 Gas Generator coupled with a rugged, industrial power turbine designed by Nuovo Pignone. The LM1600 Gas Generator is derived from the F404 turbofan aircraft engine. The power turbine of the PGT16/ LM1600 gas turbine is identical to that of the Nuovo Pignone PGT10 heavy duty, high efficiency gas turbine which has been in operation for more than half a million hours.
The power turbine shaft speed (7900 RPM) is optimized for direct coupling to pipeline, injection and process cen-trifugal compressors with a speed range that matches most operating requirements encountered in oil & gas
applications. For generator drive applications the PGT16/LM1600 syn-chronously coupled to a generator with a speed reduction gear is a highly flex-ible turbogenerator which can be oper-ated as a simple cycle or in combined or cogeneration cycle applications with an electrical efficiency close to 50%.
GENERAL SPECIFICATIONS Compressor
- Twin spool axial compressor (3 stage
GAS TURBINES
10
Aeroderivatives GAS TURBINES
PGT25/LM2500
GAS GENERATORThe LM2500 has already accumulated several million fired hours not only as an aircraft engine (TF39 and CF6-6 engines), but also in the industrial field in many mechanical drive applications (marine, onshore and offshore gas transmission) and for generator drive service. The LM2500 gas generator incorporates a 16-stage axial-flow com-pressor capable of reaching an 18:1 pressure ratio. Inlet guide vanes and adjustable stator vanes on the first six compressor stages provide for effi-cient operation over the entire operat-ing range.
POWER TURBINE
The LM2500 power turbine compo-nents were designed by Nuovo Pignone taking into account many years of experience gained in the field of heavy duty gas turbines and axial/centrifugal compressors. The aerodynamic blading was designed with the main objective of obtaining very high efficiency at both design and reduced speeds.
The 6500 rpm design speed means the turbine can have two stages with a moderate aerodynamic load and a high expansion efficiency. The two
expan-sion stages are of the high-energy, three-dimensional design type.
The investment casting superalloy selected for the blading assembly has a cobalt base for the nozzles and a nickel base for the rotor blading (i.e. the same materials used on heavy-duty gas tur-bines). A large creep and fatigue (LCF-HCF) safety margin on blade life is ensured by a moderate gas tempera-ture at the power turbine inlet. The two-stage rotor is overhung and the shaft supported by two tilting pad bearings contained in a cylindrical cartridge. The system can be easily dismantled with a simple translation of the gas generator within the package space thus reducing the time required for a major overhaul of the power turbine to a few days. Engineering simplicity and advanced materials yields long time between over-hauls and reduce maintenance costs. The turbine is assembled on a light but rigid baseplate with extensive use of prefabricated standard components preassembled and tested in the shop to minimize on-site assembly time.
GENERAL SPECIFICATIONS Compressor
- Sixteen stage axial compressor - Pressure ratio 17.7:1
Combustion
- Annular combustion chamber (30 fuel nozzles)
Turbine
- Two stage Gas Generator turbine - Two stage Power turbine (6500 RPM).
Package
- Completely mounted on a single base-plate
Combustion
- Annular combustion chamber (30 fuel nozzles)
Turbine
- Two stage Gas Generator turbine - Two stage Power turbine (6100 RPM).
Package
- Gas Generator, Power Turbine and aux-iliary systems mounted on a single baseplate
PGT25+/LM2500+ HSPT
The CF6 GCAE aircraft engines design has been applied to the LM2500+HSPT, a flexible, extremely reliable 30 MW class aeroderivative gas turbine. The LM2500+HSPT gas turbine was devel-oped for 30 MW ISO shaft power service with the highest thermal efficiency level (approx. 40%). The LM2500+HSPT gas turbine consists of the GE Aeroderivative LM2500+ Gas Generator (updated ver-sion of the LM2500 gas generator with the addition of a zero stage to the axial compressor) coupled with a 6100 RPM, 2 stage Power Turbine (High Speed Power Turbine - HSPT). Built on the LM2500 heritage and demonstrated 99.6% reliability, the LM2500+ incorpo-rates technology improvements and a large percentage of parts in common with the LM2500 to deliver the same
out-standing level of reliability. Designed for ease of maintenance, the LM2500+ also provides a high level of availability. High efficiency and reliability are among the large number of benefits contributing to LM2500+HSPT customer value.
Specialized aeroderivative annular combus-tion chamber fuel nozzles makes the LM2500+HSPT ideal for a wide range of mechanical drive (gas pipeline etc.), power generation, industrial cogeneration, and off-shore platform uses in any environment. Engineering simplicity and advanced materials yields long time between over-hauls and reduce maintenance costs.
GENERAL SPECIFICATIONS Compressor
- Seventeen stage axial compressor - Pressure ratio 21,15:1
GAS TURBINES
PGT
25
/LM
2500
PGT
25+
/LM
2500+ HSPT
LM
6000
GAS TURBINES
PGT
25
/LM
2500
PGT
25+
/LM
2500+ HSPT
LM
6000
11- The enclosure is integral with the baseplate providing maximum acces-sibility for maintenance of the gas tur-bine and auxiliaries
Emission Control
- Steam or water injection systems for NOx abatement
- Dry Low Emission (DLE) combustion system
- The enclosure is integral with the baseplate providing maximum acces-sibility for maintenance of the gas tur-bine and auxiliaries
Emission Control
- Steam or water injection systems for NOx abatement
- Dry Low Emission (DLE) combustion system
LM6000
The LM6000 is a simple-cycle, two-shaft, high performance gas turbine derived from the GE CF6-80C2 high bypass turbofan aircraft engine, the industr y standard for high-thrust engines.
Delivering more than 44.8 MW at over 42.7% thermal efficiency, the powerful LM6000 is the most fuel-efficient, simple-cycle gas turbine in the world. Direct drive provides 60,000 shaft horsepower from either end of the low pressure rotor for a wide range of electric power generation and mechanical drive applications in any environment. High thermal efficiency, low cost, and installation flexibility make the LM6000 the ideal choice as a prime
driver for utility peaking, mid-range, and base load operations, as well as for industrial cogeneration.
The LM6000’s design allows full speed range capability from 50-105% of the rated 3600 rpm rated speed. Continuing the tradition of GE’s LM2500 established record, the LM6000 is ideal as a source of drive-power for pipeline compres-sion, offshore platform, gas reinjec-tion, as well as for LNG compres-sors. The LM6000 was GE’s first aeroderivative gas turbine to employ the new Dry Low Emissions (DLE) premixed combustion system. DLE dual fuel, water or steam injection can also be used to achieve low NOx emissions.
12
Axial Compressor
The compressor rotor is made of separately forged wheels (all models except the GE5 and part of the GE10 which have a solid forged rotor). Each individual wheel undergoes inspection and is X-rayed for material flaws. In addition, each wheel is balanced individually and the rotor is bal-anced on three planes. Rabbet fits are used to ensure concen-tricity and multiple through-bolts secure the wheels to form a cor-rectly pre-stressed assembly. The blades are held in the com-pressor rotor and stator rings by dovetail platforms. The stainless steel blades provide excellent corrosion resistance and good internal dampening characteris-tics. The large chord, broad-blade compressor blades have low stresses and the unique ability to withstand damage by small for-eign objects as well as to main-tain high performance in spite of normal wear and contamination. The stator casing is horizontally split for ease of assembly, main-tenance and inspection. Iron castings give dimensional and thermal stability to maintain good radial tip clearances for maxi-mum power and efficiency. Several compressor designs are available covering pressure ratios in the 7-14 range and air flows from 20 to 400 Kg/sec with 15-17 stage configurations. The GE5 and GE10 compressors have variable geometry, imple-mented by means of adjustable vanes (inlet guide vanes and first stage stator vanes), in order to provide flow control within the operating range.
First Stage Nozzle
The complete first stage nozzle assembly consists of airfoil-shaped vanes which are contained between an inner and an outer sidewall. The design of the nozzle assembly and the arrangement for its support within the turbine shell
accommo-13
date the effects of thermal expansion caused by the hot gases and keep the assembly properly aligned in the gas path. Seals in the turbine shell prevent leakage of combustion gases around the nozzle from the inlet to the exhaust. Compressor discharge air is fed to
these sealing rings through orifices in the shell. A key feature of the first-stage nozzle is the air-cooled partition which extensively increases nozzle life. Cooled air from the compressor dis-charge is directed through the body of the individual nozzle partitions and out
holes near the trailing edge. This not only cools the metal, but blankets the trailing edge with a film of air. Additionally, relatively thick nozzle par-tition trailing edges provide increased strength and oxidation resistance, again providing longer nozzle life.
GAS TURBINE
MAIN
COMPONENTS
GAS TURBINE
MAIN
COMPONENTS
14
Buckets and Wheels
The long shank bucket design low-ers the turbine wheel rim a sub-stantial distance below the hot gas path. The high thermal resistance of the shank results in a consider-able temperature drop between the hot bucket vane and the wheel dovetail, thus reducing temperature levels and gradients in the turbine wheel and the dovetail area where rotating stresses are high. Further wheel protection is provided by radi-al seradi-als on the first-stage bucket shanks that restrict hot gas leaks into the wheel cavities. Compressor bleed air is used to cool the wheels and maintain relatively low tempera-ture levels.
The second-stage variable angle noz-zle is a unique feature of Nuovo Pignone/General Electric gas tur-bines. It is utilized on the second stage of the two-shaft gas turbines (except GE5) and has the following advantages over a fixed nozzle.
OVERSPEED LIMIT
Overspeeds which may occur principally with loss of load can be limited with the variable nozzles and turbine operation maintained without tripping. This is accomplished by opening the second stage nozzles to their maximum angle.
HEAT RATE
The heat rate can be decreased sub-stantially at light loads by maintaining
Second-stage Nozzles
15
GAS TURBINE
MAIN
COMPONENTS
GAS TURBINE
MAIN
COMPONENTS
the rated exhaust temperature, which makes it possible to maximize perfor-mance and overall fuel economy over a wide range of ambient temperatures and loads in the regenerative cycle.
MAXIMUM OUTPUT
High pressure turbine speed can be held at the rated value as ambient tem-perature changes, maintaining maxi-mum output for a given ambient tem-perature.
LOWER STARTING POWER
Less starting power is required. With the nozzles open, the pressure drop across the high pressure turbine is maximized. Thus the turbine develops more power in starting.
Combustion System
The GE5 employs a single annular com-bustor made of Hastelloy X with 18 dual-fuel nozzles similar to proven aircraft engine designs. The nozzles are provided with a pilot flame and pre-mix dry low NOx system (25 ppmv on Natural Gas). The system has the capability to alternate between liquid and gas fuel at any load.
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Liquid Gas Pilot
Gas Premix
Spark
Pressure Transducer
Liners
Burner Heat Shield
Baffles
Fuel Systems
Maximum fuel system flexibility is available on most Nuovo Pignone gas turbines. Liquid fuel systems cover the range of crude, distillate (diesel, Kerosene, naphtha) and residual fuel oils. Gas fuel systems handle natural and process gases with the latter spanning a nominal range of 300 BTU/SCF to 3000 BTU/SCF heating value. Combinations of multi-liquid, multi-gas and liquid and gas fuels can also be used. With dual fuel systems (liquid and gas) start-up may be on either oil or gas and change-over from one fuel to another is possible even during operation. Liquid fuel systems utilize a gear pump, a by-pass control valve and a positive-displacement-gear flow divider to distribute fuel equally among the chambers in multi-combus-tor systems. This feature increase combustor inspection intervals and yields a longer overall part life. Gas fuel systems utilize a continuous two-valve fuel flow control to cover the start-up acceleration range and maximum output flows.
FUEL TREATMENT
Heavy-duty gas turbines are capable of burning a variety of liquid fuels from petroleum naphthas to residuals. These fuels vary in hydrocarbon composition, physical properties, levels of potential pollutants and levels of trace metals. Operation with heavier fuels such as crudes and residuals subjects the tur-bine to major problems such as high temperature corrosion and turbine
foul-ing if the fuel is not properly treated. Heavier fuels are treated as follows: - Washing to remove water-soluble trace
metals such as sodium, potassium and certain calcium compounds.
- Inhibiting vanadium with magnesium compounds.
- Filtering to remove solid oxides, sili-cates and related compounds - Heating to obtain proper viscosity.
FLOW DIVIDER TYPICAL BURNER STOP VALVE SPEED DETECTOR ATOMIZING AIR (IF NECESSARY) FILTER BY PASS VALVE FUEL QUANTITY CONTROL LINK VCE FUEL CONTROL FROM TANK (2-5 ATE) SHUT DOWN SYSTEM (TRIP) FUEL PUMP FILTER FUEL NOZZLES CONTROL VALVE STOP SPEED RATIO VALVE FILTER FUEL GAS (14-20 ATE) CONTROL
SYSTEM SYSTEMTRIP SPEED RATIO CONTROL SYSTEM CONTROL SYSTEM TRIP SYSTEM PRESSURE RATIO CONTROL SYSTEM SPEED RATIO CONTROL SYSTEM DUAL GAS FUEL NOZZLES CONTROL VALVE SPEEDSTOP
RATIO VALVE FILTER FUEL GAS (1) FUEL GAS (2) (14-20 ATE)
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Lube Oil System
Nuovo Pignone gas turbines are lubricat-ed with a closlubricat-ed-loop, force-felubricat-ed lube oil system which includes pumps, coolers, filters, valves, and miscellaneous control and protective devices. Lube oil is circu-lated to the main bearings, the turbine The GE10 employs a single, slot-cooled combustion chamber capable of burning a wide range of fuels, including Low BTU gases.
All other models have multiple tubular combustion chambers contained inside wrappers. Transition pieces connect the chambers to the first-stage nozzles. The fuel mixture is ignited by automatically retracting igniters. Short crossfire tubes propagate the flame reliably and instanta-neously to adjacent chambers. An ultravi-olet flame detection system and flame sight ports are provided to monitor and inspect the flame quality. Fuel is fed into each chamber through a single, large fuel nozzle that extends into the end of the cap and liner assembly. The length and diameter of this liner permits combustion of a wide variety of gaseous and liquid fuels including natural gas, process gases, distillates, crude and residual oils as well as combinations of these.
GAS TURBINE
FUEL SYSTEMS
LUBE OIL SYSTEM
accessories, couplings, and load equip-ment. Part of the lube oil is diverted to the various hydraulic control and protection devices and functions as hydraulic control oil. The standard lube oil system has three lube oil pumps: the main pump,
which is mounted in and driven by the accessory gear, the auxiliary pump, dri-ven by a vertical ac motor, and the emer-gency pump, driven by a vertical dc motor. The lube oil tank is fabricated as an integral part of the turbine base plate and is located under the accessory sec-tion. The location of the tank is such that most of the lube oil and control oil piping is contained within the tank. The oil feed lines for the gas turbine main bearings and the load equipment bear-ings and coupling, and the control oil piping run through the base from their supply connections inside the tank. The lube oil pumps, coolers, filters and vari-ous control devices are installed in the tank and/or mounted on its top. The lube oil console (with motor-driven pump) for aeroderivative models is locat-ed near the gas turbines in the best position for site requirements. Provision is made for access to the tank interior through a manhole that has a bolted cover. An optional oil-water or oil-air radi-ator cooling system may also be sup-plied on request.
GAS TURBINE
FUEL SYSTEMS
LUBE OIL SYSTEM
TVC DPAH DPISH PCV TSH TAH TSHH TAHH TE TI PI PI AC DC PI TSHL EH LAL LSL 4 1 2 3 3 5 6
Auxiliaries
STARTING EQUIPMENT
During start-up gas turbines are cranked by an expansion turbine, diesel engine or electric motor. The starting means is connected to the gas turbine through an accessory gear and a jaw clutch. The drive shaft of the starting means is splined to receive a clutch hub for automatic engagement and disen-gagement during the starting sequence. For aeroderivative mod-els a dedicated skid located near the gas gurbine skid is provided.
ACCESSORY GEAR AND LOAD GEAR The accessory gear is mounted over the lube oil tank and is driven by the gas turbine. During the starting cycle, the gas turbine is cranked through the accessory gear by the starting means. The accessory gear also provides mechanical drive for accessories such as the main lube oil pump, fuel pump, hydraulic and seal oil pump, auxiliary generator, etc. An on-board auxiliary generator may be supplied as an option cou-pled to a special auxiliary gear shaft capable of providing all the electric power required by the turbounit wherever there is no other reliable power supply.
For generator drive applications nor-mally a load gear is required to
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Controls
GE’s newest generation of turbine control products has the control per-formance and availability expected from a world leader in the manufac-ture of gas turbines.
The MARK VI open architecture is based on: current industry standards (in order to simplify integration with all existing plant control systems); and proven experience in both SIMPLEX or Triple Modular Redundant (TMR) con-figurations (SPEEDTRONIC product family). The MARK VI control platform is flexible and scalable to address Balance of Plant or Process Control
match the electrical generator speed. The electric generator lube oil is also sup-plied by the gas turbine lube oil system.
ENCLOSURE
Turbine thermal and acoustical emis-sions can be drastically reduced by applying an enclosure on skid-mounted units. These enclosures are provided with ventilation, lighting and completely automatic fire and gas protection sys-tems and can be designed for outdoor or indoor installation.
DUCTING
A modularized inlet and exhaust system reduces overall package dimensions making units particularly suitable for installation where space is limited. Modularized inlet/exhaust systems are directly connected to turbines and include inlet air filters and silencers and exhaust silencers and stacks.
AIR FILTERS
The air filtering system is selected con-sidering the different environmental conditions in which the turbine must operate (e.g., industrial/marine/desert areas). They are designed and installed so that they can be easily inspected and disassembled for periodic maintenance. If necessary, filters may be fitted with an anti-icing system that keeps the filter inlet temperature above the dew point.
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needs in addition to all GE rotating equipment - Gas & Steam Turbines, Compressors and Generators. Over the complete range of gas turbine sizes, MARK VI offers the latest control tech-nology to address the most challenging technical applications (including DLN combustion) in both Power Generation and Mechanical Drive applications. Advanced Service and Maintenance tools provide unique Remote Technical Support capability.
CUSTOMER BENEFITS:
- One technology for all types of GE gas turbines and an alternative solution for
Integrated Controls of small com-bined cycles and compressor sta-tions, driving:
- Reduced training for operators - Reduced Spare Parts inventory - Higher availability with low
installa-tion and maintenance time, through comprehensive diagnostics and rapid troubleshooting
- Direct sensor connection with no interposing instrumentation for more reliable protection and reduced maintenance
- High resolution I/O, improved speed
control and smoother synchronization for generator drive applications - Application specific control action as
fast as 100 executions/sec for excel-lent speed control and rapid trip initi-ation, thus lowering risk of turbine damage
- Historic data storage and retrieval capabilities including sequence of events (SOE) data: Plant-wide analog trends and discrete data; compar-isons with archived data; and cause of trips analysis with consistent time definition.
GAS TURBINE
AUXILIARES
CONTROLS
GAS TURBINE
AUXILIARES
CONTROLS
( START-UP SUPPR. HP SPEED MV/V TEMP. AVER. DROOP BIAS BASE EXHAUST TEMP. DEGREES COMPR. DISCH. PRESS.FUEL DEMAND ADAPTER P.S. F/I SPEED REF. S DIGITAL SET PT LP SPEED ( MIN. FUEL ACCEL. ACCEL. SPEED RELAYS SPEED RELAYS HP SPEED LP RPM
FIRE WARM-UP ACCEL. MAX. OFF
MAX FUEL MAN. FUEL SHUT DOWN GND 50V DISCR. LVDT
SERVO VALVE HYDR. CYL.
FUEL PUMP
VCE SPLITTER
SERVO VALVE HYDR. CYL.
DISCR. LVDT
FUEL CONTROL
SERVO VALVE HYDR. CYL.
DISCR. LVDT ( ( ADAPTER P.S. F/I S HP SPEED (
COMPR. DISCH. PRESS. EXHAUST TEMP. SET PT
HP RPM
NCE
DISCR. LVDT
SERVO VALVE HYDR. CYL.
GAS CONTROL VALVE SPEED RATIO VALVE 2nd STAGE NOZZLE PRESSURE TRANS. NOZZLE CONTROL V C E G A T E
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Pipeline Standard
Units/Packages
The gas turbines manufactured by Nuovo Pignone have features that make them particularly suitable for pipeline compressor applications; Nuovo Pignone’s pipeline centrifugal compressor line complements its gas turbine line to optimize matching with
Regenerative Cycle
Although the GE5, GE10, MS3002 and MS5002 gas turbine models pro-vide top thermal efficiencies in sim-ple cycle mode, notable benefits in fuel savings can be achieved with optimized regenerative cycles. Standardized regenerators sized for different unit power are available for all of these models. The regenerators have a completely symmetrical heat exchanger design which is of particu-lar advantage in plants that undergo frequent startups and shutdowns.
Nuovo Pignone has designed and manufactured regenerators tailored for use with its gas turbines since 1979. They are made at our Massa plant which has fully equipped facili-ties for this type of production.
21
gas turbine drivers resulting in perfectly integrated gas turbine compressor units.
Specific pipeline service requirements, flexibility in meeting varying operating conditions, reliability, availability and unattended remote control are fully sat-isfied by these gas turbine and pipeline compressor lines. Direct compressor turbine couplings improve the reliability and efficiency of gas turbine-compres-sor units reducing the spares inventory. Compact integrated turbine-compressor units make for easy transportation and rapid on-site commissioning. All units are on structural steel baseplates, com-pletely shop piped, wired, instrumented and tested, ready to be shipped to the site minimizing commissioning time.
INDOOR/OUTDOOR INSTALLATION
Units may be lagged for indoor installa-tion or packaged for outdoor applica-tions; the oil console, inlet and exhaust system and control equipment may form a separate packaged module.
OPERATIONAL FEATURES
Centrifugal compressor characteristics suit pipeline operating requirements: - The maximum efficiency line is
per-fectly matched to pipeline operation requirements.
- Pressure ratios up to 1.5 with single-stage compressors and up to 2 with two-stage compressors.
- Limited number of components for less maintenance and a reduced parts inventory.
- Smooth, vibration-free operation. - Oil system in common with the gas
turbine improving reliability and pack-age compactness.
Gas turbine characteristics macth pipeline conditions and centrifugal com-pressor requirements. This makes the gas turbine the best driver for a pipeline centrifugal compressor.
- Gas turbines and centrifugal com-pressors are directly coupled. - The gas turbine maximum efficiency
cur ve practically overlaps the pipeline centrifugal compressor per-formance curve. With regenerative-cycle gas turbines where the exclu-sive variable-angle nozzle really pays off, this results in a very flat heat rate versus load curve so that the part-load rate is just slightly higher than that at full load.
- Nuovo Pignone’s two-shaft turbines employed for this service may vary operating speed from 50 to 105% of design speed. They allow:
- rapid response to changes in pipeline flow rates
- rapid smooth load take-off on start-up
- Gas turbine-centrifugal compressor units are easily automated making them ideally suited for remote control. - Piped process fluids (natural gas or crude oil) are frequently used to fuel turbines making units self-sufficient without requiring field facilities which may be very limited.
GAS TURBINE
REGENERATIVE CYCLE
PIPELINE STANDARD
UNITS/PACKAGE
GAS TURBINE
REGENERATIVE CYCLE
PIPELINE STANDARD
UNITS/PACKAGE
Gas compression is a critical opera-tion in the Oil & Gas producopera-tion chain. Therefore reliability is a key factor in the design of GE Oil & Gas natural gas compressors.
GE Oil & Gas has delivered over 200 compressor trains for gas reinjection and gas storage applications. Of the more than 350 casings supplied, 95 have a maximum working pressure higher than 7,200 psia (500 bar a). Our many years of experience in designing, manufacturing, installing and servicing these machines has validated GE Oil & Gas designs and production processes. Reliability of this rotating equipment is directly related to rotor stability and impeller integrity throughout the entire enve-lope of operating conditions and GE Oil & Gas machinery has been suc-cessfully proven by long years of ser-vice under the challenging conditions found in the Oil & Gas Industry.
Gas, Water Injection
& Gas Storage Units
22
Test Facilities
Nuovo Pignone carries out mechani-cal tests on all its gas turbines. Complete turbocompressors and tur-bogenerators, including all auxiliary eqipment, can be full-load tested on outdoor test beds complying with API, ASME, VDI and ISO international stan-dards at the Florence or Massa works. Even complete modules can be tested without having to be disas-sembled before shipment at the Massa works, because of its proximi-ty to the Massa harbour. The test beds are equipped with computer Data Acquisition Systems capable of collecting thermodynamic and mechani-cal data and computing in real time. Test facilities include a high pressure feeding system for gas mixtures (inert and flammable gases), a gas
The high level of power involved in these compression applications requires gas turbines as drivers. GE Oil & Gas pro-vides a complete range of mechanical drive gas turbines that are ideally matched to Oil & Gas applications. The extensive use of the GE MS6001 and MS7001EA single shaft gas turbine tech-nology for LNG mechanical drive applica-tions is a result of our plant integration services and the ability to optimize the design of both the gas turbine and the compressor for these applications. The result is flawless performance of turbo-compressors that have accumulated more than 100,000 hours of operation in the biggest LNG plants in the world. The ability of GE Oil & Gas to integrate, test and deliver the entire turbocom-pressor train is a great advantage to the Customer in terms of optimization of the system performance, delivery time and the efficiency of working with a single supplier.
Downstream
Plants
Gas turbine-driven centrifugal compres-sors are also used in Downstream process industries such as refineries and petrochemical and fertilizer plants that need flexible and reliable compression trains.
Nuovo Pignone turbocompressors are individually tailored to meet the cus-tomer’s performance requirements. They combine in a package unit the extensive experience gained by our company on both types of machines and the advantages of a single
Massa Plant (100 MW) Outdoor stands for gas turbine load tests c b NA TUR AL G AS MASSA PLANT
Outdoor stands for gas turbine tests and turbogroup full load tests
FROM DOMESTIC NETWORK 2BVTN 2HM GAS STORAGE d e a L U B E O I L C O N S O L E L U B E O I L TANK LIQUID GAS COMPRESSED AIR SYSTEM MOBILE VACUUM SYSTEM ELECTRIC SYSTEM D I E S E L TA N K To Test Beds f To Test Beds To Test Beds a,d,e CONTROL ROOM B CONTROL ROOM A
From Test Beds
EvaporatingT
owers
Gas turbine test
Centrifugal / axial compressor test Hydraulic dynamometer
M EASU RING S TAT IO N NATURAL GAS 2 1 FLORENCE PLANT
Indoor stands for gas turbine tests
to test beds 1-4 L U B E O I L C O N S O L E D L U B E O I L C O N S O L E C V A C U U M S Y S T E M L U B E O I L C O N S O L E B L U B E O I L C O N S O L E A C O N T R O L R O O M A D I E S E L TA N K
Shop electric generator + gear box Gas turbine test
Shop electric motor + gear box Gas turbine test : Low pressure shaft
C O N T R O L R O O M B 3 4 5
GAS TURBINE
GAS, WATER INJECTION
& GAS STORAGE UNITS
TEST FACILITIES
23
source of supply--fully integrated auxil-iary systems and high operational flexi-bility and reliaflexi-bility.
Typical applications include:
- Process air centrifugal compressor drive in ammonia synthesis plants - High power centrifugal or axial
com-pressor drive in Gas to Liquids plants - Production of compressed air from the turbine axial compressor section and compressor drive in air fractionating processes.
GAS TURBINE
GAS, WATER INJECTION
& GAS STORAGE UNITS
TEST FACILITIES
chromatograph for gas analysis, a 60 Hz generator, low and high pressure gas coolers, and steam and lube oil supply. The cooling towers allow closed-loop tests up to 90,000 HP. Nuovo Pignone also tests complete plants on site; the customer.
Florence Plant (100 MW) Outdoor string and load test stand
Florence Plant (100 MW) Indoor string and load test stand
Testing Facilities
Type of Test
Standard and full load tests by hydraulic 4 2
dynamometer on gas turbines indoor outdoor test stands test stands Standard tests on high power turbines 8 4
outdoor outdoor Special load and/or string tests on test stands test stands turbine-compressor and
turnine-generator units
HSPT LM2500 spin test 1
-spin test bunker
NA TURAL GAS c a,b,c,d Steam System COGENERATION PLANT I N D O O R T E S T S TA N D S FLORENCE PLANT Stand Utilities COMPRESSED AIR SYSTEM ELECTRIC SYSTEM LIQUID GAS Back Pressure TO INDOOR AND OUTDOOR STANDS e FROM INDOOR AND OUTDOOR STANDS FROM DOMESTIC NETWORK OUTDOOR STANDS Air cooler GAS STORAGE 2BVTN 2BVTN 2HM TO OUTDOOR STANDS 5 - 8 TO OUTDOOR STANDS 1 - 4 MEASURING ST A TION e Cooling Water b a d Evaporating Towers Condenser Steam generator
TO INDOOR STANDS FOR GAS TURBINE TESTS 1 - 4
8 I N D O O R T E S T S TA N D S M O B I L E V A C U U M S Y S T E M 7 a 7 b 2 4 3 1 5 FLORENCE PLANT
Outdoor string and load test stands
Centrifugal/ axial compressor Gas turbine test
Shop electric generator + gear box
C O N T R O L R O O M B L U B E O I L TA N K C O N T R O L R O O M A 6
Six Sigma
Quality Program
GE Oil & Gas turbines are manu-factured and tested in Florence, and Massa.
The entire production process is carried out under the GE Oil & Gas Quality System that integrates the GE Six Sigma Quality Program with ISO 9001 Quality Standards to guarantee satisfaction of customer expectations. The Program insures the long-term stability and sustain-ability of process improvements guaranteeing the quality of prod-ucts.
The quality program is described in the Quality Assurance Manual which documents the policies established for the quality of cen-trifugal compressors and is the Company’s reference for all depart-ments that perform quality related operations.
Specialized testing and measure-ment facilities available to support the GE Oil & Gas quality assurance program include:
- Special laboratories accredited by SINAL (National System for Accreditation of Laboratories), equipped for testing to determine mechanical properties, chemical analysis and spectrometer analy-sis, fatigue tests, macro and micrographic examinations (opti-cal microscope and scanning electron microscope).
- A Calibration Center certified as an SIT (Italian Calibration Service) Center to control the reference standards used to calibrate all measuring and testing instru-ments used in the Company Plants.
GAS TURBINE
SIX SIGMA
QUALITY PROGRAM
RESEARCH &
DEVELOPMENT
GAS TURBINE
SIX SIGMA
QUALITY PROGRAM
RESEARCH &
DEVELOPMENT
25Research &
Development
Product excellence is a moving target that can only be achieved through constant improvement and innova-tion. This philosophy drives Research & Development activities to maintain the leadership in providing the most advanced products for the Oil & Gas Industry.
The combined talents of GE Oil & Gas research engineers together with hundreds of scientists and engi-neers from GE’s Corporate Research
& Development Center located in Schenectady, New York form a team dedicated to advancing the state of the art of turbomachinery. This team is constantly working to exploit the lat-est developments in advanced materi-als and leading edge engineering design to produce machinery with high-er phigh-erformance and longhigh-er life for the Oil & Gas Industry.
The most modern computer-aided design tools such as CFD
(computa-tional fluid dynamics) and 3D Auto CAD modeling are used to produce designs that are then proven in fully instru-mented, computerized test facilities for both components under development and full scale machines. These advanced engineering tools are augmented with proven, quality-centered development processes such as tollgate procedures and New Product Introduction processes that have been the mainstay of product development throughout the entire GE family.
26
Global Services
GE Oil & Gas Global Services provides a complete set of ser-vices to support the entire gas turbine product line. We offer an extensive portfolio of proac-tive and interacproac-tive service products such as condition-based maintenance and long term service agreements com-plementing the traditional ser-vice offerings of OEM spare parts, repairs, and field ser-vices.
Our innovations are not limited to mechanical engineering. We have developed business solu-tions such as remote monitor-ing & diagnostics to help drive customer value by providing higher equipment reliability, availability, and productivity at a predictable cost.
Other advanced information-based developments include electronic parts catalogs, and e-commerce solutions.
Global Services engineers are backed up by the new product design engineering groups of GE Oil & Gas and by GE Corporate Research & Development --hun-dreds of creative minds working to provide the high-tech prod-ucts and business solutions for the 21stcentury.
Training
GE Oil & Gas offers Training for the Operation and Maintenance of our complete line of machinery and equipment.
This Training can be provided either at the client’s site or at the Learning Center located at GE Oil & Gas head-quarters in Florence, Italy.
Instructors are field-seasoned experts who combine their understanding of
theory with practical experience.
The quality training that they provide is a prerequisite for improving the skills of operating and maintenance personnel to assure safety and superior equip-ment efficiency and availability.
CLOSE TO THE CUSTOMER
Courses and documentation are designed to meet the customers’ needs
focusing on the GE Oil & Gas machinery actually installed at their sites.
EFFECTIVENESS & EFFICIENCY Traditional training tools are augmented by computer-based training and interac-tive multimedia technology.
Courses and technical literature can be provided in a variety of languages.
27
GAS TURBINE
GLOBAL SERVICES
TRAINING
GAS TURBINE
GLOBAL SERVICES
TRAINING
28
Natural Gas Reinjection plant 36xMS5002 Gas Turbines - Hassi R’ Mel - Algeria
LNG plant MS5002 Gas Turbines Point Fortin - Trinidad - Venezuela
UPSTREAM
Installations
MS5002 Turbounits for LNG and Ammonia Synthesis Ras Laffan Mesaieed - Qatar
Single lift module for offshore application - PGT 25 Gas Turbines Bongkot Field - Thailand
29
MIDSTREAM
Installations
Two PGT 25 and PCL 603 Pipeline Compressors Sbikha - Tunisia
Trans-Med Pipeline Cape Bon to Sicily
Head-Station 25MW Gas Turbine Driven Booster Compressors. Five compression units driven by MS5002 Regenerative Cycle Gas Turbines Cape Bon - Tunisia
LM2500 Gas Turbines and PCL 802 Pipeline Compressors - Feriana - Tunisia
2 Turbounits along the Transmediterranean Pipeline LM2500 turbines PCL 804 Pipeline Compressors - Messina - Italy
Crude Oil Pipeline Station 6x25 MW Gas Turbine Driven Centrifugal Pumps - Egypt
30
4 MS5001 and 3 MS3001 Gas Turbines and 2BCL 406B Compressors
Rhourde Nouss - Algeria
MS9001 Turbogenerator units for Refinery plant - Livorno - Italy
MS5001 Turbogenerator units for
Refinery plant - Sannazzaro De’ Burgundi - Italy MS5001 Turbogenerator units for Fertilizer plant
Mesaieed - Qatar
DOWNSTREAM
COMK/MARK 769/II - Design by Studio T
re
Fasi - Printed by: Sagraf - 1-2004
Nuovo Pignone S.p.A. Via Felice Matteucci, 2 50127 Florence - Italy Tel. +39-055-423211 Fax +39-055-4232800
e-mail: info.geoil&[email protected] www.geoilandgas.com