Trend of Gas Turbine Technology

Asian-born Gas Turbines for CES

Kawasaki Heavy Industries, Ltd

2008.4.2

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 Kawasaki Heavy Industries, Ltd.
Organization as of April, 2006

President Tadaharu Ohashi

Headquarter
Aerospace
Technical Institute
Rolling Stock
Gas Turbine & Machinery

Consumer Product

Kawasaki Plant Systems, Ltd Kawasaki Shipbuilding Corp.

Split Off as of Oct. 1, 2002
Earth Technica Co.,Ltd.(*)
Split off as of Apr. 1, 2005

(*)Note:Joint Company with Kobe Steel Ltd.

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 Gas Turbine Division Product
Industrial Marine (Naval)
L20A Gas Turbine SM1C
GPB180 Package Marine Gas Turbine

1.5MW Co-Generation L20A 20MW Class

Aero (Civil) Aero (Defense)

A320 V2500Engine CH-47 T55Engine

(Production Sharing Partnership)

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 History of Kawasaki Industrial Gas Turbine
From Small to Medium with own Technology
1943 ● Completed the first gas turbine engine for aircrafts in Japan
1952 ● Started overhauling jet engines
1972 ● Started development of industrial gas turbine
1974 ● Completed first S1A-01 type : 200kW gas turbine
1977 ● First Kawasaki gas turbine genset : 200kW delivered
1979 ● First genset to overseas customer delivered
1984 ● First Kawasaki Gas Turbine Co-generation system 2x1.0 MW delivered
1985 ● Accumulated delivery of 1,000th set
1988 ● 1.5MW M1A-13 type gas turbine completed
1993 ● 5.5MW M7A-01 type gas turbine completed
1995 ● 1.5MW M1A-13D Dry Low NOx type gas turbine completed
1998 ● Overseas sales and service affiliates were established in the U.S., Germany and Malaysia
1999 ● 6.5MW M7A-02 type gas turbine completed
● 5.5MW M7A-01D Dry Low NOx type gas turbine completed
● Accumulated order of 5,000th engine
● Experimental ceramic gas turbine completed and achieved the world record of 42.1% in 300kW class
2000 ● 18MW L20A gas turbine completed
2001 ● Akashi Works NO.4 Power Plant of GPC180D : 17.6 MW commercial start-up
2005 ● Akashi Works Energy Center, which comprises 24.7MW Combined Cycle and
7.8MW Flexible Heat and Power Gas Turbine Power Plant, start-up
2006 ● 7.7 MW class M7A-03 type gas turbine completed.

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 Evolution of Industrial Gas Turbine
8000 (Units)
Number of Engine Products 7000
5000
30 4000
3000 L20A
2000
10 1000 M7A-02 M7A-03
M7A-01
HGT
Output Power (MW)

3 M1A-23
M1A-13 M1A-23B
M1A-03 SMGT
M1A-01 M1F-03
1
S2A-01 S7A-01

ACT90
0.3 S1C-05
S1A-01 S1A-02
CGT
302
S3A-01
0.1

0.03
S5A-01

0.01
1970 1975 1980 1985 1990 1995 2000 2005 2010 Year
Standby /Peak-cut Base Load(Continuous) National Project

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 Special Features of GTG for CHP
Large size GTG for utility
1. Stable power demands 60

50
Steam Demand

2. High electrical efficiency Demand Max. June

Steam Demand [t/h]

40

3. Continuous operation
30

20
Demand Min. Jan.

4. High reliability with high price

10

0
0 2 4 6 8 10 12 14 16 18 20 22 24

Time [hr]

Small & Medium size GTG for CHP (CES)

1. Fluctuated heat and power demands 60
Power Demand
Demand Max. August

2. High CHP efficiency 50

Power Demand [MW]

40

3. Continuous/DSS/WSS operation 30

20
Demand Min.
May

4. High reliability with relatively low price 10

0
0 2 4 6 8 10 12 14 16 18 20 22 24

5. High starting reliability Time　[hr]

DSS: Daily Start and Stop, WSS: Weekly Start and Stop

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 Key factors for CES Business
• Less use of scarce primary energy sources
• Lower investment cost
• Lower O&M cost
• Lower emissions
• Reliable heat and power supply

• Highly efficient GTG for CHP(CES)

• Fuel flexibility
• Low lifecycle cost (LCC) design
• Glocal (Global and local) maintenance service
• Low NOx emission
• Reliable equipment supply

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 GPB180D
Gas Turbine Generator Set

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 GPB180D (L20A) Gas Turbine
Lower life cycle cost for power production

Concept of Development:
-Lower Fuel Cost, High Efficiency
High TIT, High Pressure Ratio
-High Exhaust Gas Energy
Reasonably High Exhaust Gas Temperature
-Low Emission
Dry Low Emission system

Design:
-Low Cost Design
Minimum Compressor & Turbine Stages
Compressor 11 Stages, Turbine 3 Stages

Low Maintenance Cost:

-Robust & Long Life Design

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 GPB180D (L20A) Gas Turbine
Design Specification
Air-Inlet Compressor
Output
Turbine No.2 Bearing
Thrust
Bearing Combustor
No.1 BRG

Exhaust

Generator End 17.84MWe (ISO,100%CH4)) Type Single shaft

output
Dimension L6.6m×H2.7m×W2.2m
Rotating speed 9420 rpm
Inlet air flow 58 kg/s Weight 14Ton

Pressure ratio 18.3 Compressor Axial 11 stages

Turbine inlet 1250 ℃ Combustor 8 cans
temp.
Exhaust gas 542 ℃ Turbine Axial 3 stages
temp.
Emission NOx < 23 ppm (O2=15%) Specifications are subject to change without
CO < 25 ppm (O2=15%) prior notice.

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GPB180D Gas Turbine Generator Set
Performance

Specifications are subject to change without prior notice. Catalog Jun.2007

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 Kawasaki Heavy Industries, Ltd
Facilities for GPB180D
Kawasaki Heavy Industries Engine Assemble Engine Test Cell
Complete Engine Power Section Complete Engine Power Section
Akashi works at Akashi at Akashi

turbine blade

Kawasaki Heavy Industries High-speed Balancer Packaging

Complete rotor Assembly Gas Turbine Enclosure
Kobe works at Kobe at Kobe

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Japan KHI Akashi Japan Chiba-Minato Iran KPIC

Japan Osaka Gas/ Japan Mitsubishi/ Japan Mitsubishi/

Daihatsu Kawajiri Shiohama

Malaysia PML Korea GwangMyeong

References

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 Chiba-Minato Power Station

Japan

Chiba
Owner : Summit Mihama Power Corp. Prefecture
Specifications - Combined cycle power generation system
- GTG Type GPB180D
- Electrical Output 49MW (GTGx2, STx1)
- Steam 65 t/h (0.83MPaG)
- Fuel City Gas
- NOx 5 ppm (02=16 %)

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Chiba-Minato Power Station
System Flow

Electricity is bought by
PPS and sent to
consumers through
utility network

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 Chiba-Minato Power Station
General Arrangement

Main Building L20A GTG

CCR/E&C/BOILER

S/T Generator Cooling Water

HRSG Tower Supply

Chillers &
Air Comp.

Area: 6500 m2

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 GwangMyeong CES

Korea

GwangMyeong
Owner : Samchully City

Specifications - GTG Type GPB180D x 2 (KHI supply)

- STG x 1
- Electrical Output 46MW @15 degC
- Hot water 120 t/h @15 degC
- Fuel City Gas

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 GwangMyeong CES System Flow Diagram
STEAM
FUEL TURBINE

HOB

HRSG
HOT WATER
SUPPLY
GAS TURBINE

DH
HEATER WATER
HRSG RETURN

GAS TURBINE

SIMPLIFIED SYSTEM

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Maintenance

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 Inspection Schedule

Engine Inspection Plan (Continuous operation, 0 – 140000 E.O.H. hr year)

Inspection Level Inspection Interval (E.O.H x10000 hour)

Inspection D Initial Bore scope (IBI) 500hr. - - - -

Inspection C Bore scope inspection (BSI - 4 7 10 13

Inspection B Hot section inspection (HSI) 1,2 5 8 11 14

-
Inspection A Overhaul (O/H) 3 6 9 12

E.O.H
x10000 1 2 3 4 5 6 7 8 9 10 11 12 13 14
hour

D:Initial D

C : BSI C C C C

B: HSI B B B B B B

A: O/H A A A A

year** 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

** Year : Continuous operation reference E.O.H. 8750 hours per Year

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 Bore scope Inspection (BSI)
INLET COLLECTOR BORE SCOPE BORE SCOPE BORE SCOPE COMBUSTOR BORE SCOPE EXHAUST DUCT
INSPECTION COVER INSPECTION HOLE 2S I / HOLE 5S I / HOLE 10S TRANSITION DUCT I / HOLE 3N
IGV, 1R 2R, 3R 5R, 6R 10R, 11R 1B 5R, 6R 5R, 6R

Bore scope Inspection

REMOVED
COMBUSTOR,
LINER, T/D

Bore scope

Screen

"Bore scope" is an instrument to inspect internal areas of the gas turbine. It is a combination of flexible optical fibers and an illuminating lamp to allow direct look
around the scope head. The bore scope inspection is done at site. This maintenance work can be executed without disassembling casings. The flow path inside
the gas turbine can be inspected visually by the bore scope through inspection holes and disassembled combustor casing openings.

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 Hot Section Inspection (HSI)

Remove Main Housing

Combustor Inspection Turbine Inspection

In order to maintain hot section parts at site, the gas turbine is designed to be able to disassemble hot section casings. The hot section inspection makes it
possible to inspect all hot section parts and replace almost all of them at site. But a certain maintenance space at site is necessary for this maintenance work.
If there is any likely defective part, which needs detailed examination, restore the turbine section by using a spare one of the defective part, and examine and
repair the removed defective part separately.

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 Hot Section Inspection (HSI)

Turbine Inspection

12
2 14
1

3,9 13

4,10

5,11 Inspection Parts & Location

1 Combustor Liner
2 Transition Duct
3 –11 Turbine
15 6
7 8
12 Main HSG
13 Nozzle Support
14 Seal Wall
15 Inner/Outer Diffuser

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 Overhaul (O/H)

"Overhaul" is executed at Kawasaki factory in Japan. This overhaul inspection is done to check the condition by close examination of all gas turbine parts by
disassembling them completely including the compressor. Life-controlled parts and repairable parts are replaced. After examining and replacing work, the gas
turbine parts are cleaned and reassembled. High speed balancing of the rotor assembly and mechanical running test of the complete gas turbine are done to
confirm the soundness.

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Merits of O/H with Engine Exchange

1. Minimized down time

2. Overhaul at GT manufacturing facility
3. Works under Certified Quality
Management System
4. Works with qualified engineers and
technicians
5. Best O/H facilities with good environment
6. Complete tests including high speed
balancing

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Remote Monitoring

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 Techno-Net System
Professional staffs monitor & support customers
Site

Telephone/
Internet Internet
Techno-Net server

Kawasaki Gas Turbine

World Business Centers
Kawasaki
Group
Domestic
Site Gas Turbine LAN
Monitor

Maintenance Monitoring
Supporter Technical advisor Staff

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 Gas Turbine Monitoring
Kawasaki Techno-Net System
KMS
KHI Seishin Site More than 250
Japan
Akashi … Techno-Net Clients
Japan
KMS
Server
Server Japan Central &Japan Eastern
Server
Site
Site
Europe
…
KGE USA
Frankfurt Server KGTA
Server Huston
…

Server
Asia&
… Middle east
KGA
Site Kuala Lumpur

Global remote monitoring Reduction of serious failures

• Remote monitoring • Enforced monitoring
through telephone net • Diagnosis
• Internet monitoring

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Customer
Korean Customer Services
Maintenance Equipment Spare&Tool
Operation Schedule Un- Spare GTG Sets Site tool
schedule Mngmnt TechnoNet &Spares

KMS Korea

Information
•Communication in Korean language TechnoNet
•O & M training (Site)
•First-aid maintenance support Emergency
Spares
•Schedule maintenance
Tools
•Domestic spare & tool management Korea

Kawasaki Japan
•Technical support for better availability TechnoNet
•O & M training (Class room)
•Global spare & tool management Capital By Air / Ferry
&Critical
•Logistic support spares
•Schedule maintenance
Tools
•Technical advisor supply
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 Topics

• Rising GTG Package price

• GT development trend
– Fuel flexibility
– Low emission
• Investment cost

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 Thank you
고맙습니다
Get
Reliable Contact point:

Eco-friendly
Kawasaki Machine Systems Korea, Ltd.

Park, Jeong-Min

Energy
e-mail : [email protected]
Tel : (032) 821-6945
Fax : (032) 821-6947

Now
Mobile : 010-6329-8911

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