Our upgrade solutions
OpFlex* Steam Turbine AGILITY
Steam turbine start-up can be a significant contributor to overall combined-cycle start time and variability due to complex processes with multiple operator touch points and conservative operating limits. OpFlex is an integrated, plant-level control approach. This level of automation provides enhanced combined cycle start times, reduced variability, and reduced fuel consumption.
Steam Turbine AGILITY is a comprehensive system solution to improve start times of combined-cycle plants. It includes a combination of controls upgrades with expert plant-level operational analysis and recommendations to deliver significant improvements in combined-cycle start performance.
Key features**
- One-button start
- Enhanced rotor stress control
- Flexible hot start
- Automatic temperature ramping
- Modified reverse flow
- Inlet Pressure Control (IPC) Setpoint Tracking
Benefits
Increased HP/IP efficiencies
Steam path warming
GE has developed a robust system to allow customers the flexibility during start-up by ensuring temperature uniformity across shells.
Shell warming
This upgrade is intended for the HP/IP shell (single-shell configuration), and is designed to enable the unit to maintain a set temperature for the turbine shell, and to reduce transient shell deflections, also targeting reduced seal wear corresponding to longer sustained HP/IP section efficiencies.
When combined with GE AGILITY™ offering, there will be added benefit in reduction of start times (cold, warm, and hot). The offering consists of a heating blanket system, junction boxes, cabling, thermocouples, and a stand-alone control system.
Benefits:
- Faster start up times (e.g. 0.5 – 1 hour reduction)
- Works with OpFlex*
- Longer sustained HP/IP section efficiencies
- Reduces likelihood of rub induced vibration events
Steam turbine heat conservation system (STHCS)
The STHCS uses heated air to keep the high-temperature rotors warm during periods of standstill and prior to re-start. This solution reduces start-up times by eliminating cold start conditions as well as providing preservation of the steam turbine and condenser by maintaining humidity control when the unit is in stand-still mode.
Implementing the ST heat conservation system will prevent the steam turbine from entering a cold condition after the shutdown. The warm-keeping of the ST leads to the following benefits:
- Improved availability through reduced start up times
- Improved start-up efficiency
- Enhanced flexibility by shorter response time upon demands from grid
- Avoidance of penalties for late delivery to the grid
- Steam turbine lifetime improvement
Solutions
Turbomax 7+ Stress Controller
The power generation industry is rapidly changing, and turbines originally manufactured for base-load operation are now required to respond quickly to grid demands. The modern requirements for steam turbine power plants (including combined-cycle installations) are faster and more frequent start-ups, combined with longer phases of low load operation (LLO).
Our solution for a new energy environment
GE has developed a modern rotor stress controller called Turbomax* 7+—available for units running older versions of Turbomax*—that is built around the following modules:
- Steam Turbine Rotor Stress Calculation Model
- Lifetime Usage Indicator
- Steam Turbine Limiter and Control Functions
Calculates the thermal stresses for the steam turbine rotors based upon existing measurements typically available in the turbine supervisory instrumentation suite.
Accumulates lifetime consumption during operation caused by thermal low-cycle fatigue and creep. This indicator adapts to the changing use of the asset over time.
Keeps the operation of the steam turbine within the permissible limits for protection of the asset.
Benefits
Turbomax* offers several benefits for operating and maintaining the steam turbine:
- Improved availability and reliability
- Improved flexibility
- Cost savings during start-up and load ramps
- Visibility of lifetime consumption
- Improved maintenance planning
- Enhanced optimization with digital add-ons
Related upgrades and services
Contact us
Want to learn more about steam turbine flexibility upgrades?
*Trademark of General Electric Company
**Control system limitations may apply
