Westinghouse Gas Turbine Maintenance Manual
EBooks W501f Gas Turbine Maintenance Manual are currently available in. Individual westinghouse gas turbine maintenance manual may have more than.
Developed jointly by FIAT Avio Power Systems also known as FAPS (now EthosEnergy) and Westinghouse Electric, the W501D - Westinghouse name for TG50D5 - is a huge single-shaft unit that operates at 3600 rpm to generate 60Hz power and drive a two-pole generator. The continuous over-the-years evolution of the engine led to important improvements in terms of ratings to around 110MW. Thermal efficiency is 31% in simple cycle single-shaft use; it can be brought up to 45% in combined cycle gas/steam turbine systems. The W501D is equipped with an electronic control adjustment system designed and developed by FAPS to provide the maximum in automation, reliability, and operational safety.
Special attention is given to design and development of cooling systems for the hot-section components, both during transient conditions and normal operation. Moreover, combustion system upgrades to Dry Low NOx technologies are available to reduce pollutant emissions. EthosEnergy is able to provide customers with complete product and service solutions for their Westinghouse W501D gas turbine. When you need service for your W501D gas turbine, call EthosEnergy and benefit from our OEM know-how!
This article possibly contains. Please by the claims made and adding. Statements consisting only of original research should be removed. (January 2010) Part of Westinghouse Power Generation group, the Westinghouse Combustion Turbine Systems Division (CTSD) was originally located, along with the Steam Turbine Division (STD), in a major industrial manufacturing complex, referred to as the South Philadelphia Works, in Lester, PA near to the. Before first being called 'CTSD' in 1978, the Westinghouse industrial and electric utility gas turbine business operation progressed through several other names starting with Small Steam & Gas Turbine Division (SSGT) in the 1950s through 1971, then Gas Turbine Systems Division (GTSD) and Generation Systems Division (GSD) through the mid-late 1970s. The name CTSD came with the passage of energy legislation by the US government in 1978 which prohibited electric utilities from building new base load power plants that burned natural gas. Some participants in the industry decided to use the name 'combustion turbine' in an attempt to gain some separation from the fact that the primary fuel for gas turbines in large power plants is natural gas.
Commonly referred to as a, a modern combustion turbine can operate on a variety of gaseous and liquid fuels. The preferred liquid fuel is No.
2 distillate. With proper treatment, crude and residual oil have been used. Fuel gases range from natural gas (essentially methane) to low-heating-value gases such as produced by gasification of coal or heavy liquids, or as by-product gases from blast furnaces. In fact, most gas turbines today are installed with dual- or multi-fuel capability to take advantage of changes in cost and availability of various fuels.
The story of lists the many 'firsts' achieved during the more than 50 years prior to the sale of the Power Generation Business Unit to Siemens, AG in 1998. As indicated below, the history actually begins with the successful development of the first fully US-designed jet engine during World War II. The took place in 1948 with the installation of a 2000 hp W21 at Mississippi River Fuel Corp. Gas compression station at Wilmar, Arkansas, USA. Contents. Early history Westinghouse has a long history in the industrial and electric power steam turbine industry dating back to the late 1800s and early 1900s. The steam turbine manufacturing plant in Lester, PA was built in 1917-1919 greatly expanding the company's manufacturing capacity.
As it was known become a key part of the original Westinghouse Electric Company's industrial complex, complementing other large factories in and. Westinghouse history with gas turbines began in the early 1940s with the contract signed in 1943 with the US Navy Bureau of Aeronautics to develop the.
An outcome of this was the establishment in 1945 of the, with headquarters in Kansas City, Kansas, until it closed in 1960. During the late 1940s, Westinghouse began applying its gas turbine technology to industrial land-based prime movers. A summary of the early applications can be found in an ASME paper presented by Westinghouse engineers at the 1994 ASME International Gas Turbine Conference in the Hague. It is entitled 'Evolution of Heavy-Duty Power Generation and Industrial Gas Turbines in the United States' and it also provides good summary of the Westinghouse gas turbine technology development through the mid-1990s. The following compilation is based on information in that ASME paper as well as other sources as cited, and upon personal accounts of Westinghouse engineers who had direct experience or close connections to the material presented. Early Land-Based Applications Westinghouse experience with land-based gas turbines started as early as 1945 with the development of a 2000 hp (1500 kW) gas turbine generator set, the W21. It had a thermal efficiency of 18% (LHV).
The first application of the W21 in an industrial setting was in 1948 as a gas-compressor drive installed at the Mississippi River Fuel Corp. Facility located at Wilmar, Arkansas. Reports have it that this was the first industrial gas turbine in the world to accumulate 100,000 hours of operation before it was retired. By 1948, Westinghouse also built an experimental 4000 hp with the Baldwin Company (Chester, PA) that used two of these units. Initial operation was on the Union Pacific Railroad burning distillate fuel oil. Later, operation was on the Pittsburgh and Lake Eire Railroad using residual oil fuel.
The vast majority of the early applications of Westinghouse land-based gas turbines were for industrial mechanical drives in the petro-chemical industry, both in the US and abroad. Large multiple orders were placed by pipeline companies looking for compressor drives to be placed at remote locations. But by the mid-1950s gas turbine power plants were becoming recognized as a practical alternative to steam turbine generators for certain applications, first for industry and later for electric utilities. For industrial 'total energy' applications, the important factor was that gas turbines, combined with heat recovery boilers, offered a higher power-to-steam ratio than the traditional back-pressure steam turbines used to supply both power and process steam.
So, gas turbines were put to use for combined heat and power by the petrochemical industry, working hand-in-hand with companies like Westinghouse, well before the word entered the modern lingo some 30 years later. Note is added here to acknowledge the pioneering work by Westinghouse in the unique application of a.
The engine was used to drive a 12,500 scfm fan to blow air into a blast furnace, and the design requirement was to use blast furnace exhaust gas as its fuel. The engine was modified so that all compressor discharge could be removed and fed to an external burner, from which products of combustion were returned to drive the turbine. Typically, blast furnace gas has a heating value of less than 100 Btu/scf, one-tenth of that of natural gas.
Pioneering Power Generation Applications Westinghouse sought application of its gas turbine technology in the power generation industry, which, after all, was the primary focus of its business. If the gas-turbine side of the business was to grow and thrive, it had to find its way into the power generation sector. West Texas Utilities among the first In 1952, West Texas Utilities, Stockton, TX, helped pioneer power generation application of gas turbines with the installation of a Westinghouse model W81, rated at 5000 kW. That was followed by a second W81 in 1954 (possibly 1958 based on a second source).
Both units were used in continuous (base load) operation and the exhaust heat from the second unit was used to heat feed water for a steam boiler at the site. In 1959, it was integrated with a fired boiler to form a 'combined cycle' (gas and steam) power generating system. Five years later, in 1964, the same utility installed the first pre-engineered combined cycle power plant at its.
The Westinghouse gas turbine used for that application was a supercharged model W301, nominally rated at 25MW. The rating on the steam turbine was 85MW, for an overall combined cycle plant output of about 110MW, and the thermal efficiency achieved was more than 39%, the record for gas-fired power plants in the US for quite some time. The W301, the first Westinghouse direct-drive (3600RPM) unit, was the immediate predecessor of the model W501, introduced in 1967/68 with an initial rating of 40MW (ISO/gas). (Note: some ratings listed in early publications used NEMA site conditions, i.e., 1000 ft elevation and 85F, which reduces power output by 7.5% below that at ISO (sea level, 15C or 59F conditions.)) SoCalEd and Garden State Paper install 'total energy system' In 1967, Westinghouse supplied a 15MW W191 pre-packaged gas turbine generator for a pioneering on-site industrial combined heat and power (CHP) or 'cogeneration' application.
The Southern California Edison Company (SCE) partnered with the Garden State Paper Company (GSP) to install and operate an on-site gas-turbine generator and heat recovery system to supply all the energy needs of a patented de-inking process to produce clean newsprint from used newspapers. This unique early example of a 'total-energy' system provided the operating flexibility, operating economics, site compatibility, and reliability to make it the ideal solution for both partners. SCE supplied both electricity and heat energy while GSP enjoyed the advantage of low cost, reliable on-site energy located at the process plant. The gas turbine generator was electrically tied to the SCE grid, which took the excess power generated.
Florida wastewater treatment study guide. This Study Guide was prepared as a study aid for small water treatment plant. Florida Rural Water Association does not condone the use of any of the. Your certificate of completion is good for five years, so your state exam for C and B (if. He joined the team at Florida Rural Water Association in 1996 where he. Thomas from Merritt Island, Florida. Wastewater Treatment Concepts. I recently took and passed the Florida Wastewater Certification Exam as I am.
Henry Vogt Co. Supplied the fired heat recovery boiler with a standby forced draft fan for backup duty.
The plant went commercial in January 1967. Dow Chemical's early venture into gas turbines The first five production W501 engines were installed during 1968 to 1971 to supply power and steam at Dow Chemical facilities in Texas and Louisiana. The fact that Dow had previously installed four W301 units at its Texas Division, Freeport, TX, was key to their decision to go ahead with the follow-on orders for the larger W501 units. In fact, the prototype supercharged W301 installed at Freeport, TX in 1965 was Dow’s first venture into gas turbines for on-site power generation, and Westinghouse remained a major supplier of Dow’s gas turbines for years to come. The first W501A installed by Dow Chemical at its Freeport, TX, complex in 1968 was supercharged to enhance performance and available exhaust energy.
Lm 6000 Gas Turbine Maintenance Manual
Small 'helper' steam turbine, coupled to generator was used for starting the gas turbine. In early applications, Dow typically used gas turbine exhaust as pre-heated 'air' for fully fired boilers. Supercharging fans provided flow to boilers (via bypass duct) in event of gas turbine outage. Salt Grass Combined Cycle – a major milestone Although not built as a Dow-owned facility on Dow property, the, using 4xW501 units (1xW501A, 3xW501AA), was built as a dedicated power supply for Dow’s Freeport, TX, expanding operations. The plant was designed, built and owned by Power Systems Engineering (PSE) in 1970-1972. (PSE was later incorporated into DESTEC Energy after being acquired by Dow in 1989. DESTEC later morphed into Dynegy a major independent power generating company.) Unlike most industrial generating plants, there was to be no process steam requirement for the Salt Grass plant; all output from the plant was to be in the form of electric energy.
The design objective was to use the largest gas turbines available and, based on prior experience, to use unfired heat recovery boilers for operating simplicity and improved reliability. All steam was used to drive 4 identical 25MW steam turbines coupled to the gas turbines at the outboard end of the generators (which in turn were mounted on the cold compressor-end of the rotor). The plant comprised four separate single-shaft combined cycle units for maximum operating flexibility. It also included a start-up boiler to enable the steam turbines to be used to start the gas turbines. Construction of the Salt Grass plant began in January, 1970 and the first GT unit was operational 12 months later, according to a joint PSE/Dow paper presented at the time. Westinghouse records show that he fourth GT was in commercial operation early in 1972, so the entire plant was completed in just over two years. PSE was founded by two ex-Westinghouse engineers from the Houston field sales office, Tom McMichael (Sales Engineer) and Al Smith (District Manager).
As such the both had a unique relationship with Dow and had been instrumental in previous Westinghouse business with Dow. According to a paper co-authored by Al Smith in 1971, the idea for the plant was conceived by PSE and Dow in early 1969. The Salt Grass plant was their first venture after they decided to go out on their own. The Great Northeast Blackout of 1965 It is well known that there was an increase in the birthrate in the northeastern US and parts of Canada during the summer of 1966.
This was just one of the results of the which took place on November 9, 1965, nine months before the mini baby boom. Another, somewhat more important result to Westinghouse CTSD was the birth of the modern gas turbine industry in the U.S. Although the actual culprit behind the massive power outage was found to be a single faulty relay at a transmission station in Ontario, Canada, the 'cascade' or domino effect on downstream trunk lines caused the entire CANUSE system from Canada, through Buffalo, NY and to the east coast from New York City to Maine to fail in 15 minutes. An important ramification of this event was recognition of the need to strengthen the grid and improve system restart capabilities.
Electric utilities throughout the U.S. Were mandated by their regional 'Reliability Councils' (e.g. NERC for the northeast) to increase their system reserve margins by installing a certain percentage of their overall capacity in the form of smaller localized fast-start generating units, much of them with ‘black start’ capability to assure that large plants and grids could be restarted in the event of another major outage. It didn’t hurt that the summers of 1966 and 1968 saw major summer heat waves and record peak demands, and that the base load demand on the US electric utilities were growing at a steady 6% to 7% annual rate. There was already a boom for large coal-fired steam plants and this growth was seen as going on for the foreseeable future. A Wave of Gas Turbine Installations The result was a wave of gas turbine generator installations, chosen as the fastest and most economical way to meet the mandate for reliability and to meet the steady growth of demand.
(Ergo, the Westinghouse CTSD 'The Economic Choice' marketing campaign at the time.) Annual utility purchases of additional units became a routine event as long as the peak load demand continued to increase. Based on comments from Westinghouse CTSD sales veterans, large orders of multiple units were often taken over the phone, as repeat customers raced to obtain their annual allotment.
Tracking the regional and national peak demand curves became the main tool to planners who had to forecast the market and set the shop 'load plan'. (This writer wonders whether the GT suppliers of that time developed ' reserve agreements' as was the practice adopted during another boom period, 30 years later.) Accordingly, most gas turbines installed in the US during the late 1960s and early 1970s were applied as simple cycle peaking units ('peakers'), intended for system backup and intermittent use, and installed to maintain adequate reserve margin.
Importantly, the early 1970s also witnessed the success of the early combined cycle plants and, as the peaking market started to level off, and, for the time being, this helped sustain the U.S. Utility market for large gas turbines. One report has it that the demand for gas turbines in the U.S. Hit almost 9 GW in 1969, a 30-fold increase over the total of 300 MW sold in 1961.
(The chart below shows that market for larger units (20MW) peaked at around 7GW.). US Gas Turbine Market Data - source: Gas Turbine World Magazine May–June 2011 (with permission) No wonder that forecasts for future market growth were so optimistic. At the start of 1970, Turbine Topics, the internal newsletter of the Small Steam & Gas Turbine Division (predecessor of the Gas Turbine Division) contained this statement from the Marketing Department: 'The sum total of all this tells us that the fantastic growth of the 60s will perpetuate into the 70s'. (Source: Personal collection.) However, by 1971/1972 the market had already shown signs of weakening, and, unfortunately, subsequent global events had a lot to say about whether that rosy forecast would come true. US gas turbine market from 1965-1990, with forecast to 2000, (at right) shows how the northeast blackout of 1965 accelerated the growth of electric utility market for gas turbines in the US.
Later events, most notably the 1973 Arab Israeli war, followed by the 1974 OPEC oil embargo and the U.S. Fuel Use Act of 1978, caused a steep decline. A strong recovery followed with the rise of the Independent Power Producer ('IPP') cogeneration market under the Public Utility Regulatory Policy Act (PURPA), upheld by the US Supreme Round Rock - A case of some very bad timing Based on the surge of gas turbine business in the late 1960s, Westinghouse (following the example of market leader and archrival General Electric) decided to build a modern new gas turbine manufacturing plant at Round Rock, TX, near Austin. However, by the time that the plant went into operation around the 1972 timeframe, the US market for gas turbines was about to collapse due to the impact of the 1973 Arab-Israeli war and subsequent fears of fuel supply instability due to the OPEC oil embargo (see market data chart, above). Also, unlike GE’s Greeneville,SC, plant, the new Round Rock factory was not built as a stand-alone plant with full manufacturing capabilities, as already existed in Lester.
Major components were shipped from Lester (and other suppliers) for final assembly at Round Rock. As the market collapsed (see chart, above), it didn’t take very long for Westinghouse management to act reduce the surplus of shop space allocated to gas turbines. Since Round Rock could not survive on its own, it was ultimately abandoned as a gas turbine manufacturing facility in 1976. Other large rotating equipment operations moved in, such as those of the E. Pittsburgh DC products and Buffalo Large Motors Division.
Ultimately, the large motors operations of Westinghouse were sold to Taiwan Electric Co. (TECO) and the plant is now owned by TECO-Westinghouse, and is used to serve its wind generator business. Technology evolves rapidly as market grows In spite of the fact that it might appear to have been a sellers’ market for peaking units during the late 1960s/early ‘70s, there was still fierce competition for market share.
Besides having adequate shop space to serve the market, the major manufactures (i.e. Westinghouse) were in a race to find ways to lower the price ($/kW) of their offering to get the competitive advantage. This was also the time when the jet engine manufacturers, GE and Pratt & Whitney (and a number of third-party 'packagers') entered the market with their packaged units. These proved to be very quick to install and highly efficient, and gained a lot of attention. (Efficiency was not as important as price since only intermittent use was planned for them.) The key to lowering $/kW was to increase engine power rating. This was achieved in two ways: First, be able to offer a larger unit than the competition (and with the W501 Westinghouse did just that and was able to make up for its relatively low volume vs.
Then, once the basic frame size is set, incremental rating growth can be achieved by increasing turbine firing temperature (i.e., 'turning up the wick'). Evolution of the W501 model Following the introduction of the W501A in 1967/68, Westinghouse technology quickly continued to evolve as turbine inlet temperatures increased by means of improved internal cooling and advanced metallurgy, and pressure ratios increased with improved compressor designs. Over the period from 1968 to 1975, the W501 progressed from the W501A (40MW), W501AA (60MW), W501B (80MW) and the W501D (95MW). The next major redesign was the W501D5, introduced in 1981, initially at a rating of 96.5MW (growing to 107MW (gross) ca.
In 1995, the W501D5A upgrade was offered with a rating of 120MW. In the late-1980 and early-1990s, Westinghouse introduced the advanced 501F, initially rated at 150MW (nominal). The first commercial start-up date for the 501F was in 1993 (four units, installed at the Florida Power & Light Lauderdale Station repowering project). A similar technology evolution path was followed for the smaller geared model W251 (see referenced ASME paper by Scalzo, et al.) shows how that model actually led the way to some of the technology steps taken in the evolution of the W501.
(See Scalzo, et al. For tables showing evolution of both the Westinghouse and W251 gas turbines.).
Note progression in turbine rotor inlet temperature and number of cooled rows (turbine vanes and blades). The W501A was immediately preceded by the W301, the first direct-drive design.
The upgrade involved adding two stages to the compressor (one fore and one aft) and a new turbine design with a cooled first-stage vane. Note: At the same 1994 ASME Gas Turbine Conference where the above-referenced ASME paper by Scalzo, et al.
Was presented, Westinghouse also delivered a paper announcing plans to develop a 250MW-class gas turbine, the 501G. To be designed by the Westinghouse/MHI/FiatAvio alliance, (MHI, a long-time licensee, had also collaborated with and funded Westinghouse in the development of the 501F) the design featured a steam-cooled transition duct, another of many industry firsts for Westinghouse (see Appendix I). The first 501G was installed at The City of Lakeland (FL) McIntosh station and was first synchronized to the grid in April, 1999. The W251 model series evolves along with W501 As mentioned above, the W251 model series followed an evolutionary path from the venerable W191 (ranging from 15MW to around 18MW over product life, with more than 180 units sold) and was introduced in 1967, just prior to the W501. The W251A, at a nominal rating of 20MW, was the first to feature cooling of first-stage turbine vane and other stationary parts.
In 1985, when the W251B10 was rated at approximately 45MW, the W251 product line charter was moved to Westinghouse Canada. The W251, at half the rating of the W501, was popular for smaller applications, and about 230 units were sold. The final design before being dropped from the product line ca. 1998, the was a 50MW class gas turbine, built at Westinghouse Hamilton, Ont.
With gear driven generator, the W251 could be used in 50 Hz as well as 60 Hz applications. Westinghouse Gas Turbine Engine Design Features From the earliest of its heavy-duty gas turbine designs, Westinghouse has retained time proven mechanical design features that have endured for more than 50 years and have been emulated by other manufacturers.
This from early (ca. 1990) Westinghouse sales documents for the 501F provides a list of these features. Note the cold-end generator drive feature, original with Westinghouse and later adopted by others (including the industry leader in its own F-class design). This is ideal for heat recovery applications and avoids the need for a high-temperature flexible drive coupling in the exhaust end (characteristic of earlier designs of others). Also, the two-bearing rotor design avoided the need for a high-temperature center bearing buried in the hot section of the engine (also characteristic of earlier designs of others).
Not mentioned on the list is the patented tangential exhaust casing struts designed to maintain rotor alignment. Westinghouse Packaged Gas Turbine Power Plants Westinghouse pioneered in the development of pre-engineered packaged gas turbine generator power plants, both with the EconoPac, a complete modularized simple cycle package, and with the PACE combined cycle plant. This section is empty. You can help. (March 2016) The Westinghouse EconoPac packaged GT power plant Note: ' EconoPac' is a registered Trademark of Siemens Energy Corp. As the gas turbine engine technology evolved, so did ideas on how to best package all of it auxiliary supporting systems.
In addition to the gas turbine itself, the scope of supply included the generator/exciter, a starting motor, the mechanical and electrical auxiliaries, and the inlet and exhaust systems. In 1962 Westinghouse introduced the concept of a pre-engineered packaged gas-turbine power generating unit with the W171 (12,000 kW) unit sold to the City of Houma Light & Power Co.
This early application established the basis for the ' EconoPac' simple cycle packaged plant which became the standard scope of supply for Westinghouse simple cycle gas turbine units to this day. The Westinghouse ' E conoPac'includes the factory-assembled skid-mounted gas turbine engine, generator and exciter, starting package, mechanical (lube oil, hydraulics, pneumatics, etc.)and electrical/control auxiliary skids, inlet system (filter and ducting), exhaust system (ducting, stack and silencer), all coolers, fans, pumps, valves, and interconnecting piping.
Enclosures for all skids are also included in the standard scope of supply. Typically, the EconoPac defined the gas turbine scope of supply for extended scope plants (cogeneration, combined cycle, etc.) as well as a simple cycle unit. Illustrates major components and arrangement.Full gas turbine power plant would arrive at site in pre-packaged modules for quick field assembly. The glycol cooler was used for hydrogen-cooled generator,which was standard scope before availability of large air-cooled generators for the application. Air-to-air cooler next to exhaust stack is for cooling of rotor cooling air, a feature of Westinghouse gas turbine packages. Westinghouse PACE Combined Cycle Power Plants As in the case of the simple cycle gas turbine pre-engineered and packaged plant, Westinghouse also pioneered with the idea of a pre-engineered combined cycle plant.
Around 1970, a design group was organized under the leadership of Paul Berman, Manager PACE Engineering, and the Marketing and Sales team went into high gear with an all-out promotion campaign. Was developed around the use of two 75MW W501B gas turbines and a new 100MW single case steam turbine specifically designed for the application.
The plant was called the PACE Plant (for Power At Combined Efficiencies) and the first design was dubbed the PACE 260 to reflect the nominal power rating of the plant. The PACE design was geared towards the 'intermediate load' market (between peaking and base load) where there was a growing need to install capacity that was more economical to install than base load (coal and nuclear plants) and more economical to operate than simple cycle gas turbines. The equipment had to also be flexible enough to be able to withstand the stresses of daily start-and-stop operating duty. Special provisions were made throughout the design to accommodate this cycling mode of operation. The PACE 260 concept (and later the upgraded PACE 320) was captured in this image depicting the thermodynamic cycle behind the plant design. As can be seen the original concept included supplemental (duct) firing of the two-pressure heat recover boilers, which were a vertical flow design configuration. The basic configuration was described as a 2-on-1 design, meaning that two gas turbines produced steam to feed one steam turbine.
Supplemental firing was utilized to increase steam production so as to fill the 100MW single-case steam turbine. In the initial design, approximately 20% of the fuel input was fired in the duct burner. Without supplemental firing, there is typically adequate energy in the exhaust of the gas turbine to generate enough steam to produce about 50% of the gas turbine power, or, in this case, only 75MW. In this way, the original PACE plant design had built-in steam turbine capacity to enable the water/steam side of the plant to remain essentially the same as the gas turbine power rating evolved through to the 100MW-plus W501D5, when the rating of the plant was 300MW without supplemental firing. The PACE 260 was initially offered with a heat rate of about 8,100 Btu/kWh (42% efficiency) LHV on natural gas fuel.
The upgraded (ca. 1980) PACE 320 based on the W501D, had a nominal 300MW rating and a heat rate of 7,530 Btu/kWh (45% efficiency) LHV on natural gas fuel.
PACE plants were available either with full-enclosure buildings to cover all but the heat recovery boilers, or for outdoor installation, with the EconoPacs providing the necessary enclosures for the gas turbines and their auxiliaries. For the early PACE plants Westinghouse designed and manufactured the heat recovery boilers at the Heat Transfer Division in Lester. Later plants incorporated heat recovery units supplied by subcontractors. An of PACE plants shows units sold and installed as of the mid-1980s. Note that several of the installations included two PACE 260 plants (mirror image plant designs were available for those cases).
These were called PACE 520 plants. It is also noted that nearly half of the plants were built in Mexico, one PACE 260 and two PACE 520s. The first PACE 260 was installed at the, in Lawton, OK, entering commercial in 1973. Based on published information, time from commitment to the design program (Jan. 1970) to commercial operation was less than three years. Reference is made to ASME paper 74-GT-109, by Paul A. Berman, Westinghouse Manager of PACE Engineering, which describes the PACE concept in detail and documents the construction and start-up of the Comanche plant.
Since its installation, some 40 years ago, the plant went through major boiler modification (seen in photo below), several engine performance upgrades and has operated for many years as the most economical plant on PSO’s system. (This writer recalls being told that the initial price for natural gas at the site was $0.26 per million Btu!) As of this writing, the plant is still in use, albeit not for continuous duty. The three early PACE plants sold to CFE (PACE 260 at Palacio Gomez and ) involved an order for six (6) W501B gas turbines and represented the largest order placed by CFE up to that time.
The story has it that the order was received on a Good Friday (ca. 1973?) after a very contentious competition with another major US supplier who used some rather 'creative' ways to enhance plant performance. Everyone involved in the negotiation was anxious to get home for Easter, but not so anxious that they left before getting the order.The final plant on the list was built for CFE at Tula, Mexico, as a phased-construction project, where the four (4) W501D EconoPac units were shipped and installed on an ASAP basis,in simple cycle mode, to meet an energy emergency during 1979-1981. The HRSGs and steam turbine portion of each plant was added later and the exhaust stacks were removed. (Photo below is of artist's concept of converted plant.
The four W501D EonoPacs were already in place at time of photo.) The rise of US Cogeneration and Independent Power markets As shown earlier the U.S. Market for gas turbines enjoyed a substantial boom for simple cycle peaking units following the Northeast Blackout of 1965.
And that, in turn, led to the advent, around 1970, of the popular pre-engineered combined cycle plant, such as the Westinghouse PACE and GE STAG (STeam And Gas) plants which enjoyed much early success in the early 1970s. There was much promise sustained growth in the gas turbine business. The breakout of the Arab-Israeli war of 1973 changed all of that. Following the war, Arab members of the Organization of Petroleum Exporting Countries (OPEC) imposed an embargo against the United States, and other countries in Europe and South Africa, in retaliation for the U.S. Decision to re-supply the Israeli military. The almost immediate result of the embargo was severe shortages in target countries such as the US, and a steep rise in the global price, of oil and oil products. Had become increasingly dependent on imported oil and the embargo caused a major disruption of the national economy.
First the Nixon administration, then the short-lived administration of Gerald Ford, and, finally, that of Jimmy Carter, all developed plans to increase domestic production and reduce the use of imported oil. At the same time, during the, there was a strong concerted move in the natural gas industry for deregulation, and a supply shortage of pipeline gas was created to punctuate their position.
A direct result of all of this tumult in the energy supply chain was Jimmy Carter’s National Energy Plan of 1977 and a declaration of Energy Independence. Legislation was introduced in the U.S. Congress aimed at establishing strict prohibitions and regulations aimed at achieving reductions in the use of both imported oil and natural gas.
(It should be noted that this is being written at time of a glut of both oil and natural gas in the U.S.) At the time there was clearly a strong pro-coal leaning in Congress, and coal, as the most abundant domestic energy source in the US, was being promoted as offering the way to achieve independence from imported oil. 'King Coal' was in the driver’s seat, and the future of coal-fired power generation seemed assured in spite of the environmental laws and regulations that had been passed only a few years earlier. After months and months of debate (much which this writer witnessed in person) the National Energy Act of 1978 was passed and proudly signed into law by Jimmy Carter. Two of the major provisions of the new energy legislation had profound impacts on the gas turbine industry: First, The Fuel Use Act ( FUA), which, among other things, prohibited the use of oil and natural gas as fuel for new base load power plants.
Only 'alternative fuels' – i.e., coal and coal-derived fuels – were allowed for that purpose. (Again, in today’s environment, can anyone imagine??). Peaking units and intermediate-load combined cycle power plants (. This section is empty. You can help. (March 2016) The physical move south by Westinghouse Power Generation started in 1982 and initially was done to consolidate the non-manufacturing operations of the Steam Turbine Division located in the Philadelphia, PA area and the Large Rotating Apparatus Division (i.e. Generators) located in the Pittsburgh, PA area.
The selection of Orlando, FL as the new home for the Steam Turbine Generator Division came after a process of elimination of several other 'neutral' locations. The story has it that Richmond, VA had been the first choice for the new Westinghouse Power Generation headquarters, but the ongoing legal issues between Westinghouse and a major Virginia-based utility over nuclear fuel contracts but a damper on that idea.
Westinghouse purchased a large tract of land called The Quadrangle located just across the road from the sprawling campus of what is now called the University of Central Florida and built a large new office building. Prior to moving into the new building, the Steam Turbine Generator Division headquarters was located in an abandoned shopping center.
On the move. In October, 1986 the long expected notice was received by employees: CTSD (a.k.a. CTO - Combustion Turbine Operations) would be moving to Orlando to join the Steam Turbine Generator Division (STGD) operation which had moved south from Lester and E. Pittsburgh 4–5 years earlier.
The actual move took place in April, 1987 when all of those making the move were to report to work at their new location at The Quadrangle, Orlando, Florida. Prior to the move, early in 1986, the newly formed Power Systems Business Unit management team, headquartered at the Energy Center in Monroeville, PA, and now in charge of Power Generation (as well as the Nuclear Energy segment), had formed a Power Generation Task Force. The objective was to better understand the future of the power generation industry, and how Westinghouse could best position itself to grow and prosper in it. A renowned industry consultant was hired to conduct a market study, and it was then, finally, that the importance of gas-turbines to the future of power generation in the U.S. – if not worldwide – became appreciated.
As indicated earlier, this had not been the general view of the old-guard power generation management, and Westinghouse had already started to execute its plan commonly known as ' phased exit' from the gas turbine business. The small group (under 100) that moved with CTO quickly grew through 'Project Backfill'. A substantial number of STGD engineers and managers, as well as many professionals and managers from nuclear projects and engineering operations, and, also, personnel from Westinghouse Canada, found new career opportunities in rebuilding the organization.
After moving to Orlando in 1987, CTO was incorporated into the Generation Technology Systems Division (GTSD). But his organization proved to be short-lived as Westinghouse Power Systems formed the Power Generation Business Unit, in 1988. Just after the move, a promotional brochure was produced called: ' On the Move', aimed at assuring customers, the rest of the industry, and employees, that Westinghouse was still in the gas turbine business. It also told of another recent big change, i.e., reaching agreement with Mitsubishi Heavy Industries (MHI), a long-time Westinghouse licensee, to manufacture the W501D5. (While the W251 was still to be built at Westinghouse Canada, Hamilton works, the Lester plant closed in 1986.
) According to the announcement in the brochure, Westinghouse CTO was to continue in the role of technology developers, system and plant designers, application engineers, marketers, project managers and service providers. As it turned out, depending on MHI for shop space to supply Westinghouse's market needs did not work out very well, nor did it continue for very long. In 1991, PGBU management saw fit to end the agreement with MHI and to resurrect the Great North American Factory by using the Pensacola, FL plant for assembly of the W501D5. Other Westinghouse plants involved in the manufacture of Westinghouse gas turbines included those in Charlotte, NC, Hamilton, Ont., and Winston-Salem, NC. Take A New Look At Westinghouse Combustion Turbines Another big part of the advertising campaign following the move to Orlando was the theme: ' Take a new look.at Westinghouse Combustion Turbines'.
The message was clear. The marketplace had to be reassured that 'engineering excellence and proven technology' along with 'full customer service' were ongoing constants with Westinghouse, in spite of the major changes that had taken place. Another new marketing theme: ' Westinghouse – the new value in combustion turbines.' It was apparently felt necessary by Westinghouse, in 1988 –- 40 years after the first Westinghouse industrial gas turbine was placed in operation and after a long history of industry firsts and solid accomplishments—the new management team in Orlando went to all the industry media with the message to let the world know that Westinghouse was still around with a new commitment to its gas turbine business. Bellingham and Sayreville: major cogen project milestones Within a year after the move to Orlando, two additional major orders for-cogeneration projects were obtained to help restore Westinghouse’s position in the marketplace. Two identical PACE 300 (2-W501D5 GT on 1-100MW ST) power plants were ordered by Intercontinental Energy Corp., a family-owned private-power IPP development company located in Massachusetts.
These were the Bellingham (MA) and Sayreville (NJ) cogeneration projects, and they were instrumental in restoring confidence in Westinghouse's gas turbine business - to the outside world, to the new management of the Power Generation Business Unit, and to CTO employees. It is interesting to note (from editor's personal recollection) that the prime competition for the Bellingham and Sayreville project orders, after the customer had already broken off discussions with GE, was Fluor-Daniel Corp., which was offering Siemens/KWU V84.2 100MW gas turbines. In addition to some very effective negotiating skills on the part of Westinghouse, KWU’s relative lack of 60 Hz experience was rumored to be a strong factor in the customer’s decision to go with Westinghouse. The Bellingham and Sayreville projects were developed under the rules of the PURPA energy legislation of 1978. In the case of the Bellingham plant, the developer achieved Qualifying Facility ('QF') status in a unique way by supplying a slip stream of exhaust gas to feed an adjoining process unit for production of beverage-grade CO2 sold to a nearby soda bottling plant. For the Sayreville project, the owners found a more conventional means to achieve QF status by exporting steam for process use at a nearby chemical plant.Today both the Bellingham and Sayreville 'Energy Centers' are owned by NextEra Energy Resources, Both the Bellingham and Sayreville plants were supplied by Westinghouse PGBU under turnkey contracts, as was another important milestone cogeneration combined cycle plant built around the same timeframe in New Jersey, the approximately 150MW Newark Bay Cogeneration facility, which uses two 46.5 MW W251B10 gas turbine units.
Introduction of the 501F Advanced Gas Turbine As noted earlier work by Westinghouse CTO on the advanced 150MW-class 501F started in Concordville two years before the move to Orlando. This new engine was being co-developed with Mitsubishi Heavy Industries (MHI), a decades-long Westinghouse licensee, acting in a new role as design partner, investing in the development, and working alongside Westinghouse engineers. The design target was a 2300F (1260C) rotor inlet temperature, with a mature rating expected to be around 160MW. The introductory rating was set at 145MW with simple cycle heat rate of 10,000 Btu/kwh or 34% efficiency.
The combined cycle efficiency being advertised at the time was 'better than 50%'. Although the 501F had many design changes and improvements to achieve higher firing temperature and better reliability, its family DNA is clearly rooted in the W501, as is evident from the list of design features cited earlier.
(Note the use 501F vs. W501F, in deference to MHI, which to this day uses the Westinghouse model nomenclature for its large gas turbine products). The prototype 501F engine was built by MHI at its Takasago manufacturing and testing facilities.
In mid-1989 it was reported in the press that the prototype unit would be undergoing full-load factory testing. The first 501F gas turbines (4 of them) were sold to Florida Power & Light Co. For the Lauderdale Station repowering project, and went into service in 1993. This was the first of several large repowering projects undertaken by the Florida utility, most of which used Westinghouse gas turbines (or Siemens gas turbines, following the Siemens acquisition of Westinghouse PGBU in 1998, below.) As noted earlier, the introductory rating of the 501F in 1988 was 145MW, when it was said that the mature rating would exceed 150MW. As shown in the adjoining curve, the growth of the Westinghouse 'F' machine over the decade 1988-1998 greatly exceeded original expectations The curve plots 501F combined cycle efficiency vs. Time, with simple cycle power rating and heat rate shown at intervals along the development timeline. Note: As of this edit in 2016, MHI offers the M501F3 at 185MW and Siemens offers the SGT6-5000F (a.k.a.
501F) at 242MW, approximately the rating of the original 501G, below.) Introducing the 250MW-class W501G Around mid-1994, two announcements were made almost simultaneously - one at the June ASME International Gas Turbine Conference at The Hague and the other at the Edison Electric Institute meeting in Seattle, WA. Westinghouse and its (then) tri-lateral alliance partners, MHI and FiatAvio announced their new W501G (or 501G) high-temperature gas turbine that would operate at 2600F turbine rotor inlet temperature. This announcement was ahead of any such similar announcements by GE or Siemens, both of which were also rumored to be working on their own high-temperature machines. The W501G was touted to be a new machine, with an advanced 17 stage compressor design achieving a 19:1 pressure ratio (vs. 15:1 for the W501F). The combustion section featured DLN combustors with.
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^ Farmer, Robert (1994). 'Steam-cooled 501G rated at 230MW with 2600F rotor inlet temperature'. Gas Turbine World Magazine. October 14, 1986. Editor - Gas Turbine World Magazine (October 1988). 'New W501D combinec cycle optimized for 307,000 kW and 7000 Btu heat rate'.
Gas Turbine World Magazine October `1988. CS1 maint: Extra text: authors list. (PDF). October 2013. LA Times (December 1, 1997).
^ Westinghouse Combustion Turbine Installations. Personal collection, editor: Westinghouse Electric Corp.
Power Generation Business Unit.