IRPC2015_ppt-Final-29-May 2015-پیوست شماره 2
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Transcript of IRPC2015_ppt-Final-29-May 2015-پیوست شماره 2
Gas Turbine Technologies: Fuel Flexibility & IntegrationGas Turbine Technologies: Fuel Flexibility & Integration
Shima shahaliOil & Gas Product Development Coordinator
Mapna Group Co.3 June 2015
1
Outline1. Introduction2. Combined Cycle Power Plant (CCPP) 3. Fuel Oil Treatment Plant (FOTP) 4. Mapna Gas Turbine Technologies5. Case study: Kermanshah Power Plant /Iran6. Result7. Recommendations (Reco’s)
2
Standard Natural Gas 39 to 46 MJ/kg)Gasoil 42 MJ/kglow‐BTU gases 10 and 35 MJ/kgSyngas 4 and 12 MJ/kg
1‐ Introduction
2‐Combined Cycle Power Plant
3‐ Fuel Oil Treatment Plant
4‐Mapna Gas Turbine Technologies
5‐ Case study
6‐Result
7‐ Reco’s
Introduction
3
Characteristics of Untreated HFO
•High viscosity•High density•Cat fines•High salt content•High vanadium content
Characteristics of Treated HFO
•Heating of HFO is required up to 120°C•Two stage washing system is required•Wash water addition of up to 10% of fuel flow
•Wash water heating is requested•Chemical dosing (demulsifier, inhibitor, etc.) requested.
Protect Our Gas Turbines
4
1‐ Introduction
2‐Combined Cycle Power Plant
3‐ Fuel Oil Treatment Plant
4‐Mapna Gas Turbine Technologies
5‐ Case study
6‐Result
7‐ Reco’s
Mechanical BOPNG & Gasoil Fuel System Gas & Liquid Fuel SpecificationGT Limitations
5
Combined Cycle Power Plant Index1‐ Introduction
2‐Combined Cycle Power Plant
3‐ Fuel Oil Treatment Plant
4‐Mapna Gas Turbine Technologies
5‐ Case study
6‐Result
7‐ Reco’s
Mechanical BOP for one BlockA.Gas & Liquid Fuel System B.Compressed Air SystemC.Fire Protection SystemD.Nitrogen SystemE.Crane, hoistF.Heating, Ventilation and Air ConditioningG.Water Treatment SystemH.Waste Water and Sewage SystemI.Auxiliary Boiler
6
1‐ Introduction
2‐Combined Cycle Power Plant
3‐ Fuel Oil Treatment Plant
4‐Mapna Gas Turbine Technologies
5‐ Case study
6‐Result
7‐ Reco’s
NG & Gasoil Fuel System Consumer Qty
Pressure(bara)
Consumption(kg/sec)
Gas Turbines 2 21 ± 2.5% 24
HRSG 2 4‐5 1.8
Auxiliary boiler 1 4‐5 0.4
Admin Mechanical room 1 3.5 0.023
Canteen Building 1 3.5 0.05
Total NG Consumption for 1 Block CCPP 26.27
7
Consumer Qty Pressure Consumption (kg/sec)
Gas Turbines 2 2.5‐8 bara 22
HRSG 2 - 0.42
Auxiliary boiler 1 1barg 0.19
Admin Mechanical room 1 1barg 0.05
Canteen Building 1 ‐ ‐
Total Gasoil Consumption for 1 Block CCPP 22.66
NG Fuel System
Gasoil Fuel System
1‐ Introduction
2‐Combined Cycle Power Plant
3‐ Fuel Oil Treatment Plant
4‐Mapna Gas Turbine Technologies
5‐ Case study
6‐Result
7‐ Reco’s
Gas & Liquid Fuel Specification
Item UnitAbadan Refinery
ArakRefinery
EsfahanRefinery
BandarAbbasRefinery
Tabriz Refinery
TehranRefinery
Shiraz Refinery
KermanshahRefinery
Density@15° C
Kg/m3
958.9 959 946.9 964.2 959.7 959.1 954.9 903.9
Flash point C 91 92 73 72 109 82 108 81Kin viscosity @50°C cSt 274.4 270.6 230.7 285.2 210.5 198.8 161.1 29.4
Vis. Red Wood @37.8°C
C 2444 2406 2007 2552 1805 1688 1311 197
Pour Point Wt% 10 10 4.4 ‐1.1 15.6 10 21.1 23.9Total sulfur Wt% 2.991 2.950 2.709 3.0 2.706 2.781 2.302 1.690Carbon R. Wt% 9.7 10.4 9.68 12.3 8.9 9.4 5.41 4.2Ash Wt% 0.057 0.03 0.027 0.047 0.035 0.047 0.034 0.008Water & sediment
Vol% Zero Zero 0.05 Zero Zero 0.04 0.05 Zero
Calorific Value
Mj/kg
42.78 42.8 43.06 42.64 42.87 42.83 43.21 44.13
Vanadium content ppm 117 123* 190* 105 149 222* 321* 38*
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Statistics for HFO Composition for 8 refineries / Iran1‐ Introduction
2‐Combined Cycle Power Plant
3‐ Fuel Oil Treatment Plant
4‐Mapna Gas Turbine Technologies
5‐ Case study
6‐Result
7‐ Reco’s
HFO consumption for each Gas Turbine is estimated around 1,000,000 lit per day.
Ni (ppm)V (ppm)Region
10 to 5050 to 500South America
10 to 10030 to 200California
5 to 1015 to 30Alaska
1 to 105 to 50Middle East
0 to 150 to 50North Africa
5 to 300 to 3S.E. Asia
Typical Vanadium and Nickel Contents
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Typical Vanadium and Nickel Contents in Fuel Oil 1‐ Introduction
2‐Combined Cycle Power Plant
3‐ Fuel Oil Treatment Plant
4‐Mapna Gas Turbine Technologies
5‐ Case study
6‐Result
7‐ Reco’s
GT LimitationsSubstance Test Unit Natural Gas Gasoil Heavy Fuel Oil
Total Dust ASTM D 3605 ppm ≤ 20 ≤ 20 ≤ 20
Vanadium (V) ASTM D 3605 ppm ≤ 0.5 ≤ 0.5 ≤ 0.5
Lead (Pb) ASTM D 3605 ppm ≤ 1.0 ≤ 1.0 ≤ 1.0
Sodium + Potassium
(Na+K) ASTM D 3605 ppm ≤ 0.5 ≤ 0.5 ≤ 0.5
Calcium (Ca) ASTM D 3605 ppm ≤ 10 ≤ 10 ≤ 10Ash ASTM D 482 ppm ‐ ≤ 100 ≤ 100
Nitrogen (N) ASTM D 4629 ppmlocally applicable
emissions guidelines
locally applicable emissions guidelines
locally applicable emissions guidelines
Sulfur (S) ASTM D 129 ppm ≤ 20 1‐4 % 1‐4%
Hydrogen sulfide (H2S) ASTM D 1945 ppm ≤ 10 ‐ ‐
Mercaptans ASTM D 3227 ppm ≤ 10 ‐ ‐
Acetylene (C2H2) ASTM D 1945 Vol. % ≤ 0.1 ‐ ‐
Hydrogen (H2) ASTM D 1945 Vol. % ≤ 1 ‐ ‐
Ethane (C2H6) ASTM D 2887 Vol. % ≤ 15 ‐ ‐
Higher molecular‐weight hydrocarbons)
CnHm (n ≥2)ASTM D 2887 Vol.
% ≤ 10 ‐ ‐
10
Limits for Chemical Contaminants
1‐ Introduction
2‐Combined Cycle Power Plant
3‐ Fuel Oil Treatment Plant
4‐Mapna Gas Turbine Technologies
5‐ Case study
6‐Result
7‐ Reco’s
Main Process Parts
1.Raw water supply skid2.Demulsifier supply skid 3.HFO Pre‐heater4.HFO Heater5.Mixers & Separators
6.Common waste treatment skid7.Vanadium Inhibitor 8.Common treated HFO storage tank9.Common treated HFO forwarding skid
11
1‐ Introduction
2‐Combined Cycle Power Plant
3‐ Fuel Oil Treatment Plant
4‐Mapna Gas Turbine Technologies
5‐ Case study
6‐Result
7‐ Reco’s
Utility Consumption for One Block (Capacity: 2*47 m3/hr)
InstrumentAir
WaterBalance
Steam & CondensateBalance
Max OperabilityHeat Duty
Electrical PowerConsumptionItem
Nm3/hrm3/hrLPCLPS
KWKWKg/hrKg/hr
2261520015200143201300Total
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Utility Consumption for FOTP ; capacity= 2*47 m3/hr
1‐ Introduction
2‐Combined Cycle Power Plant
3‐ Fuel Oil Treatment Plant
4‐Mapna Gas Turbine Technologies
5‐ Case study
6‐Result
7‐ Reco’s
Reason for FOTP System
To minimize the risk of hot temp. corrosion
Increase the life time of the turbine blades
Reduce the content of sediments drastically
Reduction of lifecycle cost of the gas turbine
13
1‐ Introduction
2‐Combined Cycle Power Plant
3‐ Fuel Oil Treatment Plant
4‐Mapna Gas Turbine Technologies
5‐ Case study
6‐Result
7‐ Reco’s
Simulation
14
1‐ Introduction
2‐Combined Cycle Power Plant
3‐ Fuel Oil Treatment Plant
4‐Mapna Gas Turbine Technologies
5‐ Case study
6‐Result
7‐ Reco’s
HFO Treatment Unit‐ One Train
15
1‐ Introduction
2‐Combined Cycle Power Plant
3‐ Fuel Oil Treatment Plant
4‐Mapna Gas Turbine Technologies
5‐ Case study
6‐Result
7‐ Reco’s
Feed Forwarding Heater Skid
16
1‐ Introduction
2‐Combined Cycle Power Plant
3‐ Fuel Oil Treatment Plant
4‐Mapna Gas Turbine Technologies
5‐ Case study
6‐Result
7‐ Reco’s
Turbine Inlet Temp versus Vanadium content
17
1‐ Introduction
2‐Combined Cycle Power Plant
3‐ Fuel Oil Treatment Plant
4‐Mapna Gas Turbine Technologies
5‐ Case study
6‐Result
7‐ Reco’s
Standard Flame tube TIT= 910 °CSpecial Flame tube for HFO TIT= 1010° C
Factor f for countingoperating hours
Contamination in the fuel in ppm
VanadiumNa+K
10.5≤0.5≤
1.50.5≤0.5 ≤ Na+K ≤ 1
1.50.5 ≤ Na+K ≤ 10.5≤
Short tip from Graph
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1‐ Introduction
2‐Combined Cycle Power Plant
3‐ Fuel Oil Treatment Plant
4‐Mapna Gas Turbine Technologies
5‐ Case study
6‐Result
7‐ Reco’s
EfficiencyNominal PowerTurbine TypeItem
38183 MWMAP2B134.6170 MWMAP2A234.5166 MWMAP2+334.42162 MWV94.2 (5)434.42157 MWV94.2 (3)53240 MWMG‐4062720 MWMG‐207
Mapna Gas Turbines Technologies
19
Mapna Gas Turbine: Types, Nominal Power & Efficiency1‐ Introduction
2‐Combined Cycle Power Plant
3‐ Fuel Oil Treatment Plant
4‐Mapna Gas Turbine Technologies
5‐ Case study
6‐Result
7‐ Reco’s
Pilot Plant for Fuel Atomization
20
1‐ Introduction
2‐Combined Cycle Power Plant
3‐ Fuel Oil Treatment Plant
4‐Mapna Gas Turbine Technologies
5‐ Case study
6‐Result
7‐ Reco’s
Case study: Kermanshah Power Plant /Iran
implemented FOTP from Ambarli PP
21
1‐ Introduction
2‐Combined Cycle Power Plant
3‐ Fuel Oil Treatment Plant
4‐Mapna Gas Turbine Technologies
5‐ Case study
6‐Result
7‐ Reco’s
General Description
22
Four (4) existing V94.2 GTalready operating with natural gas and gasoilTwo of them to operate with Heavy Fuel Oil
1‐ Introduction
2‐Combined Cycle Power Plant
3‐ Fuel Oil Treatment Plant
4‐Mapna Gas Turbine Technologies
5‐ Case study
6‐Result
7‐ Reco’s
Scope of Work
1.Inspection of existing Gas turbines 2.Modification in BOP3.Supply of first filling, Spares4.Engineering and Design Services5.Packing, Transportation, Offloading 6.Warehousing and preservation7.Civil & Installation Work8.Test and Commissioning
23
1‐ Introduction
2‐Combined Cycle Power Plant
3‐ Fuel Oil Treatment Plant
4‐Mapna Gas Turbine Technologies
5‐ Case study
6‐Result
7‐ Reco’s
Problems in Executing plan
•Modification in Existing Gas Power Plant
•Shortage of Instrumentation in FOTP & modification in the Control System of GT
•Reduction of Nominal Out Put Power
•Environmental Side Effects
• Increasing the maintenance
•Decreasing the Life time of main parts
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1‐ Introduction
2‐Combined Cycle Power Plant
3‐ Fuel Oil Treatment Plant
4‐Mapna Gas Turbine Technologies
5‐ Case study
6‐Result
7‐ Reco’s
HFO SYSTEM LEGENDUBA: LV Switchgear RoomUBD: Auxiliary TransformerUEJ: 2*1000 m3 Treated HFO Storage TanksUEL 01: HFO Untreated Forwarding Pump StationUEL 02: HFO Treated Forwarding Pump StationUEM01: HFO Treatment StationUEM02: Area for HFO Forwarding Heater SkidsUHB: Auxiliary BoilerUGC: Water Storage TanksUGD: Water Treatment PlantUGE: Neutralization Pit
HFO SYSTEM LEGENDUBA: LV Switchgear RoomUBD: Auxiliary TransformerUEJ: 2*1000 m3 Treated HFO Storage TanksUEL 01: HFO Untreated Forwarding Pump StationUEL 02: HFO Treated Forwarding Pump StationUEM01: HFO Treatment StationUEM02: Area for HFO Forwarding Heater SkidsUHB: Auxiliary BoilerUGC: Water Storage TanksUGD: Water Treatment PlantUGE: Neutralization Pit
General layout ‐FOTP Section
25
1‐ Introduction
2‐Combined Cycle Power Plant
3‐ Fuel Oil Treatment Plant
4‐Mapna Gas Turbine Technologies
5‐ Case study
6‐Result
7‐ Reco’s
Item Parameter Unit Value
1
Ambient air temperature:Design for performanceMaximum (absolute)Minimum (absolute)Annual mean of max. temperatureAnnual mean of min. temperatureDesign for HVAC systems
°C
1542‐2123.97.2
2 Site Elevation: m 1300
3Barometric pressure:Design for performance
mbar 866
4
Humidity:Design for performance MaximumMinimumDesign for HVAC systems:
%608315
5 Maximum wind velocity km/h 130
6 Ground Seismic horizontal Acceleration g 0.3
Site Conditions
26
Kermanshah Climatic Conditions
1‐ Introduction
2‐Combined Cycle Power Plant
3‐ Fuel Oil Treatment Plant
4‐Mapna Gas Turbine Technologies
5‐ Case study
6‐Result
7‐ Reco’s
Item ION VALUE
1 PH 7.4‐7.5
2 Cond. 410‐450 (µs/Cm)
3 T.H. 120‐260 (mg/l)
4 Ca2+ 110 (mg/l)
5 Mg2+ 150 (mg/l)
6 Na+ 74 (mg/l)
7 TDS 206 (mg/l)
8 Turb. 0.6 (NTU)
Raw Water Analysis
27
Kermanshah Raw Water Analysis1‐ Introduction
2‐Combined Cycle Power Plant
3‐ Fuel Oil Treatment Plant
4‐Mapna Gas Turbine Technologies
5‐ Case study
6‐Result
7‐ Reco’s
Spec. Unit ValueConstituents
C Mass % n.aO Mass % n.aS Mass % 1.69N Mass % n.aH Mass % n.a
ContaminantsWater &sediment Vol % zeroCoke residues wt % 4.2
Ash ppm 80Na+K ppm 50 (worth case)V ppm 38Pb ppm n.aCa ppm n.a
PropertiesLower heating value(LHV) MJ/Kg n.aHigher heating value(HHV) MJ/Kg 44.13Density at 15° c Kg/m3 903.9Kinematic Vis. @ 50° C cSt 29.4Flash point °C 81°CPour Point °C 23.9
Spec. Value UnitC 74.869 wt%H 25.131 wt%LHV 50035 KJ/kg
Fuel Gas Temperature 15 °C
Spec. Value UnitC 86.4 wt%H 13.4 wt%S 0.2 wt%O 0 wt%N 0 wt%LHV 42600 KJ/kg
Kermanshah Fuel Composition
28
UntreatedHFOCompositionNatural Gas Composition
Gas Oil Composition
1‐ Introduction
2‐Combined Cycle Power Plant
3‐ Fuel Oil Treatment Plant
4‐Mapna Gas Turbine Technologies
5‐ Case study
6‐Result
7‐ Reco’s
Specification Unit QuantityWater content+ sediment Vol % *
Coke residues wt % tbdAsh ppm(wt) ≤100Na+K ppm(wt) ≤0.5V ppm(wt) ≤0.5Pb ppm(wt) *Ca ppm(wt) *Fe ppm(wt) ‐Ni ppm(wt) ‐
Estimated Composition for Treated HFO
29
Estimated Composition for Treated HFO
1‐ Introduction
2‐Combined Cycle Power Plant
3‐ Fuel Oil Treatment Plant
4‐Mapna Gas Turbine Technologies
5‐ Case study
6‐Result
7‐ Reco’s
1‐Required Modification in Mechanical Equipment
2‐Required Modification in Electrical Equipment
3‐Required Modification in I&C Equipment
Required modification in GT
30
1‐ Introduction
2‐Combined Cycle Power Plant
3‐ Fuel Oil Treatment Plant
4‐Mapna Gas Turbine Technologies
5‐ Case study
6‐Result
7‐ Reco’s
Ambarli /Turkey Power Plant Main Part 6Gas Turbines(V94.2) 3 Steam Turbines
FOTP
Date of using HFO : 1994‐1996 Technology: Alfa Laval Co. Capacity: Total 240 m3/hr (4*60 m3/hr)
TIT Power OutputFuel
1050 °C139 MWN.G
1050 °C139 MWLFO
960 °C116 MWHFO
31
1‐ Introduction
2‐Combined Cycle Power Plant
3‐ Fuel Oil Treatment Plant
4‐Mapna Gas Turbine Technologies
5‐ Case study
6‐Result
7‐ Reco’s
Ambarli /Turkey Power Plant
32
Gas Oil & Fuel Oil Skids in Gas Turbine Hall1‐ Introduction
2‐Combined Cycle Power Plant
3‐ Fuel Oil Treatment Plant
4‐Mapna Gas Turbine Technologies
5‐ Case study
6‐Result
7‐ Reco’s
TIT/OTC for HFO (°C)
TIT/OTC for LFO(°C)
TIT/OTC for NG (°C)
‐1050/5251051/524Unit # 1‐1050/5251048/523Unit # 2
9981064/5211050.1/526Unit # 3
9981055/5261053.4/527Unit # 4
TIT/OTC Parameters
Power OutputWater
injected flow
Auxiliary Power Consumption
(KW)Power Output (MW)Fuel
-870 KW121.6N.G
No‐Water Injection1730118.5HFO
35% of fuel flow rate1860122HFO
Result of Performance Data
33
1‐ Introduction
2‐Combined Cycle Power Plant
3‐ Fuel Oil Treatment Plant
4‐Mapna Gas Turbine Technologies
5‐ Case study
6‐Result
7‐ Reco’s
34
Recommendation
1‐ Introduction
2‐Combined Cycle Power Plant
3‐ Fuel Oil Treatment Plant
4‐Mapna Gas Turbine Technologies
5‐ Case study
6‐Result
7‐ Reco’s
Economic Calculating (HFO/NG) is vital
Use the better coating to increase TIT
Apply automatic turbine Blades Washing
Integrate results in Process Sim (Aspen tech)by Output power modelling (Thermo flow)
35
Thanks for Attention………!!