Shanky77

FT8 Gas Turbine
Aeroderivative Gas Turbine for Industrial Applications

Engineering the Future – since 175 8.

MAN Turbo

Introduction

1 FT8 on base frame during workshop assembly
2 Cutaway view of the FT8 (with standard combustion system)

1

MAN Turbo offers the world’s most comprehensive product line of compressors and turbines. Innovation, ongoing development and modern technology guarantee the competitiveness of our products (single source solutions) for the lifetime of a machine.
Gas turbines have been included in the range of products since 1988. In 1990, the gas turbine product line was expanded by adding the FT8 gas turbine through signing a co-operation agreement with Pratt& Whitney Power Systems
(PWPS). With the FT8 gas turbine, MAN Turbo offers a prime mover, enabling customers to obtain the reliable, environmentally sound and economic technology they require for a variety of their applications.

2

2

FT8 Gas Turbine

The LPC (Low Pressure Compressor)

By mid-2008 more than 370 of the

has 8 rotor stages and 7 stator stages.

“Standard Combustion System” which

extremely successful FT8 gas turbine

The inlet guide vanes as well as the first

permits the use of various gaseous and

packages had been delivered or were on

two stator vane stages have been fitted

liquid fuels – with different specifications

order. The highly efficient FT8 gas turbine

with variable geometry. Variable vane

as well as combinations in any percent-

The basic version comprises a so-called

consists of a GG8 gas generator and a

movement provides optimum efficiency

age mix and thereby offering high fuel

PT8 power turbine (also referred to as a

for the compressor over the complete

flexibility.

“free-running” turbine). The gas genera-

speed range and excellent part-load

tor provides high-energy gas to the power

efficiency. The LPC rotor is connected

A DLN (DryLowNOx) combustion system

turbine, where this gas performs work

to the 2-stage LPT (Low Pressure

for gaseous fuel operation is available as

when mechanically coupled to a driven

Turbine) rotor by the LP-shaft which is

an option. The extremely robust DLN

load through a flexible coupling.

conducted through the tubular HP-shaft

system allows quick load changes and is

connecting the HPC (High Pressure

insensitive to changing gas compositions

GG8 - Gas Generator

Compressor)

and ambient conditions.

The two-shaft gas generator has been

Pressure Turbine).

with

the

HPT

(High

derived from the latest version of the most

Standard Combustion System

successful aero-engine in commercial

The HPC consists of seven rotor stages

In the case of the standard combustion

service, the Pratt&Whitney JT8D-219,

and seven stator stages and is driven by

system the combustion section has nine

which has achieved highest recorded

the single-stage HPT. W ith this arrange-

chambers (cans) arranged in an annulus

sales of >14,500 engines.

ment the LP-system and HP-system are

around the turbine shafts and positioned

running at their own optimum speed

between the High Pressure Compressor

without mechanical interaction.

and the High Pressure Turbine. The

The major components of the gas generator are the two compressor

combustion chambers are enclosed by

modules (LP and HP), the combustion

Combustion System

inner and outer casings. The outer casing

section and the two turbine modules

Depending on the application the FT8

can be unbolted and moved rearward to

(HP and LP).

gas turbine can be equipped with two

allow for easy inspection or removal of

different combustion systems.

the combustion chambers and fuel nozzles. 3

1 Combustion section with bur ner cans (standard combustion system)
2 FT8 gas turbine on base frame with DLN combustion system

Two combustion chambers accommo-

1

2

The centrebody pilot zone provides

is suspended in antifriction bearings

date each one spark plug. During initial

stabilisation of the lean premix flame

which are supplied with synthetic lube

ignition, a flame is propagated from these

and can be used to control combustor

oil by a common gas generator/ power turbine lube oil system.

two chambers to the remaining chambers

dynamics. The third fuel zone comprises

through integral a flame crossover tubes,

the diffusion sidewall pilot nozzles used

which interconnect all nine chambers.

for starting, low power operation and for

For power generation with grid frequen-

additional combustor stabilisation.

cies of 50Hz or 60Hz, 4-stage power

Besides the fuel flexibility, another feature

turbines are available with design

of the standard combustion system is

As for the standard combustion system,

speeds of 3,000 or 3,600 rpm for CW

its capability to utilize water injection for

two spark plugs, which are installed into

(clockwise) and CCW (counter clock-

NOx-reduction.

the annular combustor, are utilized.

wise) rotation. With this design a direct

DLN (Dry Low NOx) Combustion

As part of the design, Helmholtz resona-

(2-pole) electric generator is possible

System

tors are incorporated into the combustor

without the need for a load gear.

The DLN combustion system is based

section. The thirteen resonators provide

upon an annular Floatwall combustor

passive control of dynamic pressure

For mechanical drive applications in the

which is derived from Pratt& Whitney’s

within the combustor.

upper speed range up to 5,500 rpm,

coupling of the power turbine to the

MAN Turbo has developed a dedicated

latest design for new-generation flight engines. PT8 Power Turbine

3-stage power turbine with a variable

Different power turbines are available

sp e ed r a n ge b e twe en 2,50 0 an d

The combustion system consists of 16

for both generator and mechanical

5,500 rpm. This speed variant is mainly

lean premix fuel nozzles and 15 sidewall

drive applications. Each power turbine

employed in the oil & gas industry for

pilot nozzles which together establish a

incorporates an annular transition duct,

driving compressors for miscellaneous

3 zone fuel system to produce the desired

an axial-flow reaction turbine and a

applications.

emission levels with stable engine opera-

horizontally split main casing followed

tion. The lean premix fuel nozzles have

by the annular exhaust casing. The

2 fuel zones, a lean premix zone (main

power turbine rotor which is made up of

gas flow) and a centrebody pilot zone.

turbine disks and front/ rear shaft ends,

4

Diffuser
PT8-30/36-Power turbine

n=3,000 rpm
Collector box
Generator drive applications

n=3,600 rpm
GG8-Gas generator
Diffuser
n=5,500 rpm
Mechanical drive applications
PT8-55-Power turbine

Modular FT8 concept for generator drive and mechanical drive applications

5

Configurations

PowerPac

More than 1100 FT4 gas turbines were

A further application where the TwinPac

The FT8 PowerPac includes the skid-

built, with a large number operating in

configuration provides some advantages

mounted gas turbine directly coupled to

the TwinPac configuration.

is a growing plant capability.

the synchronous generator – mounted

In applications where the power demand

on a separate base frame – including all

As of May 2008 more than 282 FT8

gradually grows, the FT8 TwinPac

ancillary equipment required to form a

gas turbines have been sold in such

concept offers the option of future

complete package for outdoor/ indoor

TwinPac configurations.

expansion. Initially just one gas turbine

installation.

can be coupled to a generator rated for
Due to the concept of free-running

twice the power output (“½ TwinPac”),

TwinPac

power turbines it is possible to shut

and another FT8 might be added at a

A FT8-TwinPac comprises two FT8 gas

down one gas turbine whilst the remaining

later stage. All the electrical infrastructure

turbines. Each gas turbine is directly

gas turbine is kept in operation, provid-

can be further utilized so that only the

connected to a centrally located double-

ing maximum operational flexibility in the

second gas turbine package needs to

end synchronous generator. Together with

case of an occasionally reduced power

be added. The generator efficiency

the ancillary equipment, a completely

demand.

is kept almost constant in the 50-100%

self-contained package is formed either for outdoor or indoor installation.

power range. Thus, the power station
In this case the remaining unit is oper-

can be adapted to growing requirements.

ating at optimum efficiency even at 50%
This particular arrangement is only

load of the total TwinPac power

MechPac

available for the FT8 gas turbine because

output. Should this mode of operation

The FT8 MechPac includes the skid-

of the synchronous speed and the

constitute a major portion of the overall

mounted gas turbine directly coupled to

available CW and CCW power turbines.

operational time, overrunning clutches

the driven equipment (compressor) –

MAN Turbo’s partner, Pratt& Whitney

are available to avoid power turbine

mounted on a separate base frame –

Power Systems (PWPS), has accumu-

windmilling losses of the gas turbine

including all ancillary equipment required

lated many years of sound experience in

which is out of operation. The overrunning

to form a complete package for outdoor/

the U.S. with their TwinPac units which

clutches are fully automatic.

indoor installation.

are based upon the FT8 and its predecessor, the FT4 gas turbine.

6

1

2

3

1 Typical MechPac, (Plant of Wingas, Rueckersdorf,
Germany)
2 Typical PowerPac (Plant of
BOREMER, San Martin de la Vega, Spain)
3 Typical TwinPac (Plant of
Solvay, Rheinberg, Germany)

7

Package concept

1

2

3

The package concept for the FT8 offers a

minimum. An example of an installation

high flexibility as the FT8 is not completely

optimized for a building with of less than

gas turbine are mounted as a pre-

pre-packaged at the manufacturer’s work-

9 metres is shown in fig. 4.

engineered lube oil package on an

shop compared to a so-called single-lift

As an option the gas turbine package

ancillary skid – for ease of maintenance –

skid.

can be of course designed for outdoor

next to the gas turbine enclosure

Components not integral parts of the

A single-lift skid has the advantage in

installation on a "greenfield" site as well

package. This package contains for

regard of minimizing erection time but is

in order to avoid an additional building

example the lube oil reservoir, filters and

less flexible with regard to the arrange-

and to reduce the investment cost.

motor driven supply – and scavenge

ment required for indoor installations or

The gas turbine acoustic enclosure is

pumps for the power turbine.

sites with space restrictions.

equipped with its own crane system for rapid exchange of the gas turbine

The gas generator lube oil supply and

W ith the FT8 package concept the FT8

components during overhauls, thereby

scavenge is executed by mechanically

gas turbine comes to site first without

making the need of an external crane

driven pumps coupled to the accessory

an enclosure – pre-mounted and pre-

system no longer pertinent.

drive-mounted gearbox.

plate and junction boxes – with the

As a matter of course, MAN Turbo

Starting System

need of minimum space and access

provides not only supervision but turnkey

The starting system consists of a

requirements. Having placed the gas

installation of its supplied FT8 gas

hydraulic starter motor mounted on the

turbine onto the foundation, the enclosure

turbine packages.

gas generator accessory drive gearbox

wired on a base frame including the fuel

consisting of pre-fabricated compact

and a skid-mounted hydraulic start-pac.

modules is quickly built up.

Lubrication system

Like the ancillary lube oil skid, the

A further package feature of the FT8

Unlike other industrialized aero-derived

hydraulic starter skid is located outside

gas turbine is given by the flexibility of

gas turbines, the FT8 gas turbine uses a

of the gas turbine enclosure package

being able to arrange the auxiliary systems

common lube oil system for both the

and can be arranged according to the

such as the lube oil system and the

gas generator and the power turbine –

present specific space constraints.

starter equipment module on separate

based on synthetic oil – which is totally

It will supply high-pressure fluid to the

skids thereby reducing the dimensions

independent of the mineral lube oil

starter motor geared to the HP com-

of the main package module to a

system of the driven equipment.

pressor rotor shaft of the gas generator.

8

1
2
3
4

4

FT8 during erection
Assembly of gas turbine enclosure
Gas turbine enclosure
FT8 PowerPac at CMST in Graz / Austria

4

approx. 18,900 mm

1
2
3
4
5
6
7
8

1

approx. 8,900 mm

2
7

5
8

Electro hydraulic start skid
Water injection skid
Lube oil skid gas turbine
Lube oil cooler gas turbine
Lube oil skid electrical generator
Lube oil cooler electrical generator
FT8 PowerPac
Electrical Generator

3
4

6

9

Applications

1 Emergency power station of Kraftnät Aland with one FT8 PowerPac
2 Combined power and heat station II (district heating) of EVO/Germany
3 Emergency power station of Fingrid Oyj with two FT8 TwinPacs Source: Fingrid Oyj, Finland

1

2

The above-described features of the FT8 gas turbine in conjunction with its inherent package concept have mainly led to the following areas of applications for the FT8 gas turbine:

Generator Drives

been modified from a 50 MW helium

and thus for peaking applications, i.e.

W ith respect to power generation there

gas turbine installation to an ultra-

peak shaving and emergency plants.

are essentially two different modes of

moder n, automated gas turbine power

operation, namely “base load” and

station, which supplies the city of Ober-

“peak load” operation. W ithin the so-

hausen with electric power and heat

FT8 are utilized for peak shaving

called “downstream” sector (e.g. utili-

(district heating). MAN Turbo’s scope

purposes. Due to the excellent starting

ties, paper mills, chemical plants) nu-

comprises beside the FT8 PowerPac

reliability the FT8 is ideally suited for

merous FT8 packages are installed for

installation the revamping of the existing

emergency power generation as well.

Almost all peaking applications of the

base load as well as for peak load ope-

components and building structures.

ration.

The gas turbine is equipped with a standard combustion system allowing

station (fig. 1) which is equipped with

Base load

for dual fuel operation. NOx reduction is

FT8 gas turbines is one example of

Due to economical reasons most FT8

performed by means of water injection.

The Kraftnät Aland – power generation

such an emergency power generation application. The contractor is the grid

base load applications take advantage of the additional use of the exhaust heat,

Peak load

operator Kraftnät Aland of the island

i.e. are working in a cogeneration process.

Due to its aero-derivative design with

group Aland which belongs to Finland.

One example of an FT8 cogeneration

fast start-up and quick loading capability,

The PowerPac is located in T ingsbacka

plant is shown in fig. 2. The Oberhausen

the FT8 gas turbine is furthermore ideally

close to the connection point of the

Public Utilities (EVO) power station has

suited for daily start and stop operation

subsea power supply cable – coming

10

3

from Sweden – which provides electrical

transmission system including organiza-

only 5 min from standstill until reaching

energy to the island group. The purpose

tion of spinning and rapid start capacity

full load, i.e. about 100 MW. These units were taken into operation in 2007.

of the FT8 PowerPac is to maintain the

reserves in Finland. The plant, consisting

power supply for the island group in

of two TwinPacs, is located close to the

the case of a power supply outage via

nuclear power plant OL 1-3 in Olkiluoto,

the subsea cable. Furthermore the FT8

Finland. On the one hand the plant

PowerPac is being used as a peak shaver

is used to stabilize the public power

for the electrical grid of the island group.

grid and on the other hand to supply

Consequently, rapid start capability is

emergency power to the nuclear power

of extreme importance. The liquid fuel

plant in the case of an outage of the

operated unit needs only 5 min from

public grid and other emergency power

standstill until reaching full load, i.e.

supplies in order to keep the cooling

about 25 MW. This unit was taken into

pumps running. Both the stabilizing of

operation in 2005.

the public grid as well as the secured power supply to the nuclear power plant

A further emergency power station –

are of highest public interest. Of course,

based on FT8-TwinPacs – is shown in

rapid start capability is therefore of

fig. 3. The contractor is Fingrid Oyj,

extreme importance for this installation

which is in charge of the national power

too. The liquid fuel operated units need
11

1 Plant design of the Ruhrgas compressor station in Wer ne /Germany
2 FT8 MechPac at Ruhrgas’s compressor station in Wer ne /Germany
3 Three FT8 MechPacs at Wingas’s compressor station in Mallnow /Germany

1

2

Mechanical Drives

distributing companies (Wingas and

station was expanded by adding a

The outstanding efficiency figures,

Ruhrgas) rely.

waste heat recovery system utilizing

based on the two-shaft design of the

exhaust heat of the gas turbines to

gas generator and the use of the latest

The compressor station of Ruhrgas AG

produce steam for a steam turbine

developments in the aircraft industry,

in Werne, Germany, (fig. 2) is a key

driving a fourth pipeline compressor

which are maintained over a wide load

installation for gas distribution within

(delivered by MAN Turbo).

range, in combination with the extreme

Germany.

robust DLN combustion system, which

Because the Mallnow compressor station

allows quick load changes and being

In order to expand transport capacities,

is running 24 hours a day, 365 days a

insensitive to changing gas compositions

two gas turbine compressor units

year – thus a base load installation –

and ambient conditions make the FT8

based upon the FT8 were added to

steam is permanently available to power

MechPac configuration a reliable and

complement the compressor plant

the steam turbine.

thus cost-advantageous solution for

already installed. Both FT8 units are

mechanical drive applications.

equipped with the DLN combustion

In total, WINGAS operates 8 FT8

system.

MechPacs distributed on 4 compressor

Aside from mechanical drive installations

stations. All these FT8 units are equipped

for UGS (underground storage) and

MAN Turbo’s scope comprised aside

booster stations (e.g. re-gasification

from the delivery of the turbo machinery

plants) especially pipeline compressor

and its accessories the tur nkey erection

stations do have a significant share in

and commissioning of the gas turbine

the so called midstream sector.

compressor units.

Especially for the application in pipeline

At the Polish border, near Frankfurt

compressor stations, the FT8 – driving

Oder, where the JAGAL pipeline is

centrifugal compressors out of the MAN

connected to the JAMAL pipeline,

Turbo’s product portfolio – has demon-

W ingas GmbH operates a compressor

strated to be a proven and reliable con-

station which relies on three FT8

cept on which the main German gas

MechPacs. In the course of 2007 this

12

with the DLN combustion system.

3

13

Service

1 Borescope inspection on the FT8
2 Test arrangement for FT8

1

It is essential how effectively the value of the machinery is maintained especially when the gas turbines following their purchase are dedicated to have a service life running into decades.

Service concept

It is our aim to be there whenever and

Derived from these tasks MAN Turbo

Early recognition of critical machine

wherever you need us, and in consultation

has established a service concept for its

conditions and of faults or malfunctions

with you, to offer a service tailored to

FT8 product programme which offers

that are about to have an impact is an

your requirements – thereby securing

the following features:

essential safeguard for the smooth

the value of your long-term investment.

MAN Turbo operates a Pratt & Whitney

operation of the gas turbine and thus

MAN Turbo is today responsible for the

approved service shop at the Ober-

the availability of the plant as a whole.
Nevertheless experience has shown

service of around 500 gas turbines

hausen works taking advantage of the

worldwide, and has experts and special

expertise and skills developed by the

facilities at its disposal for:

OEM (PWPS)

erection and commissioning

proactive maintenance

caused not only by the core equipment

customer support and diagnosis

systems for the recording and analysis

(gas generator /power turbine / driven

spare parts procurement and job

of operating and maintenance parame-

that often unplanned shutdowns are

equipment) but also by ancillary systems.

execution

ters (remote data transmission for trend

Our approach to provide service support

corrective maintenance and inspections

monitoring and diagnosis of machine

consequently covers the complete gas

full-load testing

data)

turbine plant including all ancillary systems

materials examination

supplied by MAN Turbo.

14

2

Cooling water

Compressed air tank for air starter

Nitrogen cooler 25 MW
Throttle valve
Piping 28"

Fuel pumps FT8 Gas Turbine Package
Pipeline
compressor

compressor for air starter

Intake Silencer
Air Filter
Package Ventilation

Fuel filter Gear Box

Torquemeter

Water injection system Lube oil system

pool gas generators and power turbines

technical information in the form of

The test arrangement allows maximum

on standby for rental purposes in the

service bulletins

flexibility with regard to different speeds

event of scheduled or unscheduled

round-the-clock availability of service

of testing FT8 Gas Turbines (50Hz,

downtimes so as to minimize downtime

personnel

60Hz and variable speed in the case of

periods

company’s own government-approved

mechanical drives). Besides that, an

care, support and coordination at the

laboratory for materials examination,

option had to be left open for power tur-

works of MAN Turbo of all aspects

research and development

bines having either right or left direction of rotation. A precision dynamometer,

relating to components supplied by
MAN Turbo, including driven equipment

Test facilities

located between the power turbine and

spare parts storage at the Oberhausen

Our test facilities incorporate a dedicated

a three-shaft special gearbox, is used

works

FT8 gas turbine test stand allowing us

for measuring the power turbine torque.

exchange of main modules (gas

to test the FT8 gas turbines even at full

The gearbox steps up /down the output

generator / power turbine) and / or sub-

load. Natural gas and /or liquid fuel firing

speed of the gas turbine to correspond

modules within a minimum of time

is possible, permitting simulations of

to the speed range of a double-stage

facilities for full-load testing of the FT8

original operating conditions. The most

25 MW pipeline compressor (test stand

at the Oberhausen works (see descrip-

moder n monitoring systems allow real-

equipment) which operates in a closed

tion below)

time analysis of the gas turbine during

loop with nitrogen at pressures between

wide range of training facilities (see

the test run.

28 and 76 bar.

description below)
15

This gas turbine test is in accordance to

To achieve these targets we can offer

Should the overall plant contain other

ASME PTC-22 with standard exceptions.

you a training course that is made-to-

turbo machinery products manufactured

measure, like your gas turbine plant.

and/ or supplied by MAN Turbo, such as

Training

We take your specific requirements into

compressors, generators or steam

Skilled, motivated staff makes a major

account when focusing on the content

turbines, the subjects of the training

contribution to ensuring maximum long-

in order to establish a programme which

programmes of course are expanded accordingly. term availability with minimum service

fits best to your specific installation and

and maintenance costs. We offer you

constraints. Among other things, our

training programmes for your staff, from

training courses comprise the following

operators to plant managers. The primary

options/ services:

aims of our training courses are:

Training for specialized staff, fitters,

To complement and elaborate on the

foremen, technicians, engineers and

information contained in the operating

plant managers

manuals

Training in your company, on our

To optimize operation of the turbo

premises or a combination of the two

machinery set

Training in German, English or French

Early detection and elimination of

as well as in your native language with

critical machine states, malfunctions

simultaneous translation

and faults – including auxiliary systems

Organization and coordination of all

Prompt detection of minor damage

measures by a single body – from

that could result in more extensive

compilation of the training documen-

damage if ignored

tation to hotel bookings and outline

Use of detailed knowledge in main-

programmes.

tenance, inspection, cleaning and preservation work

16

FT8 test stand with full-load capability

17

Technical data

Power versus temperature (PowerPac)

Sea level, rel. humidity = 60%
Natural gas
No inlet /outlet losses
Standard combustion system
Generator efficiency: 98%

Power at Generator Terminals (MW)

33

30

27

24

21

18
-30

-15

0

Inlet temperature (°C)

18

15

30

45

Mechanical Drive

FT8 PowerPac

Heat rate

FT8 MechPac

-

-

25,870

HP

-

-

34,690

%

Thermal efficiency

FT8 TwinPac

kW

Shaft power

-

-

38.6

kJ/kWh

-

-

9,330

Btu/HPh

-

-

6,594

kWe

25,570

51,140

-

Generator Drive
Power at generator terminals Electrical efficiency

%

38.1

38.1

-

kJ/kWh

9,440

9,440

-

Btu/kWh

Heat rate

8,950

8,950

-

°C

458

458

457

Exhaust Gas Data
Exhaust gas temperature

°F

856

856

855

kg/s

85.1

170.2

85.9

lb/s

188

376

189

rpm

7,100/11,520

7,100/11,520

7,100/11,520

Compressor stages

8/7

8/7

8/7

Turbine stages

2/1

2/1

2/1

kg

3,000 (3,950)

3,000 (3,950)

3,000 (3,950)

rpm

3,000*

3,000*

2,500 - 5,500

4

4

3

kg

6,000

6,000

5,100

Exhaust gas mass flow

Gas Generator (LP/HP)
Speed

Weight approx. (DLN)
Power Turbine
Speed
Stages
Weight approx.

Above specifications valid under the following conditions:
15°C (59°F), sea level, no inlet /outlet losses, RH = 60 %, natural gas,

gen. = 98%

* 3,600 rpm available on request

19

MAN Turbo AG
Steinbrinkstrasse 1

In the interests of technical progress,

46145 Oberhausen/Germany

subject to change without notice.

Phone [phone]

Printed in Germany. February 2009

Fax [phone] www.manturbo.com MAN Turbo – a member of the MAN Group

Turbo 1005 e 0109 0,1 ba