Power Gen Middle East - 한국에너지공단 · Spray Injection Controlled to Enter and Cover...
Transcript of Power Gen Middle East - 한국에너지공단 · Spray Injection Controlled to Enter and Cover...
Power Gen Middle EastDoha, Qatar
Tuesday, 5 October 2010
Robert Burke – Application Engineering ManagerPer Andersson – Business Development Leader – Dubai
Pravin Lohar - Nama Development – Abu Dhabi
Application of Multi-Stage Compressor Cleaning System on Large Frame DLN Combustion Turbines
Agenda
1. Water Wash Technology and Design Process
2. Water Wash Performance Observations
3. Case Studies1. GTE WW vs. Annual Cleaning2. GTE WW vs. OEM Offline WW3. GTE WW vs. OEM Offline & Online WW(Multi-staged Compressor Cleaning System)
4. Summary & Conclusions
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Compressor Efficiency – An Operational Imperative
General Gas Turbine Energy Balance
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Increases in Compressor Efficiency = Increases to Available Power
Water Wash Design Objectives
1. Highly Atomized Spray, with Proper Momentum to Scrub Blade
- Mass Adequate to Reach Blade Surface- Mass in-Adequate to Erode Blade- Velocity Adequate to Avoid Break up enroute to Blade
2. Spray Injection Controlled to Enter and Cover Compressor Core
3. Water Quality Controlled, Ion Starved
- Absorbs Free Ions on Blade Surface- Avoids Corrosion of Blade, HGP
4. Duration and Flow Optimized to Minimize Water Usage
5. Automated Operation / Digital Plant Interface
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Water Wash Technology
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Key Design Features– Gas Turbine Specific Nozzle and Pressure Selection
• 60 to 80 bar, produce droplets 80 to 250 microns D43• Mean droplet size of 156 microns D43• Avoid droplets > 500 microns• Water temperature 60°C for fouling stability
– Nozzle Placement Optimizes Wash Coverage• One position for both Online and Offline Wash• CFD model prediction of specific gas turbine inlet
– Wash Process Minimizes Water and Detergent Volume• Wash duration 3 to 5 minuites, flow at 5 to 250 l/min• Air/Water ratio of 0.33• No detergent, no rinse for Online• Reduction of detergent need by 80% for Offline
– Automated PLC interface to Plant Control
Optimized droplets delivered at optimum momentum
Patent 5,868,860 Key Claims– Supply Pressure 50 to 80 bars– Mean Droplet range 120 to 250 microns
Water Wash Design Process: Nozzle Selection
• Laser Test measuring of water droplet size and velocity from nozzle(PDA-Phase Doppler Anemometer)
• Each Nozzle Class characterized: Size distribution Velocity distribution
SIZE COUNTS VOLUME4 9 0
21 25941 71138 33251 534355 19890 959873 10565 1142790 5123 10423
107 2484 8540124 1103 5911141 553 4369158 268 2982175 150 2267192 106 2130209 112 2897226 107 3506243 70 2834260 63 3152277 42 2511294 30 2194311 26 2258328 19 1926345 21 2430362 18 2375379 18 2851396 14 2404414 0 0431 10 2173448 0 0465 0 0482 1 254499 7 2534
100000 100000
INSTRUMENT: Dantec PDA D[10] = 48.7DATE : 2005-12-05 D[20] = 57.6NOZZLE : P/N 20508 D[30] = 70.6BEAM AIM : off-axis D[32] = 106.1DISTANCE : 30 cm D[43] = 176.8PRESSURE: 50.5 bar Dv10 = 46.9FLOW RATE : 14.50 l/min Dv50 = 115.1WAT. TEMP: 15 C Dv90 = 370.9
1 microns
FLOW THROUGH
OVERSIZE500 microns
EVAPORATION &
PREFERRED
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• Droplet Size Distribution- Mean Droplet Diameter- D43 Mean Volume Mass- D42 Mean Sauter Diameter
• D43 diameter of 80-250 µm gives the best optimization of washing results, penetration and low impact during wash
Water Wash Design Process: CFD and Nozzle Placement
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The gas turbine inlet geometry is entered intoa GTE developed CFD-code. Air flow issimulated in a k-epsilon model.
In a second step numerous particles withthe same size, mass, speed and angle asthe washing droplets are injected into theair flow field by a MATLAB code thusenabling studying the droplet trajectories.
Water Wash Design Process: Evaluation Coverage
Simplicity & Functonality in an MS7001 example:
• 9 nozzles each located midspan between each strut
• Optimized nozzle placement
• WW nozzle inserted through bellmouth
• Single position for both wash cycles- Offline WW- Online WW
• Obsolete OEM nozzles & positions
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Water Wash Design Process: CFD Optimization
• Air Flow: 289 kg/sec
• Wash Fluid 90-100 l/min
• Offline WW:70% by volume @ 25% Span
• Online WW:55% by volume @ 54% Span
20-60%span
Offline WWOnline WW
Modeled and confirmed by CFD Analysis
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Performance Observations: Comparative View
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Low Pressure Wash System Penetration Limitation High Atomizing Offline Wash
OEM GTE
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Case Studies
GTE References for different as-is configurations:
1. Paka, TNB, Malaysia, 6- off GE Frame 9E –GTE Water Wash System & Process vs. Annual Abrasive or Hand CleaningCustomer also reporting benefits of GTE vs. other systems
2. Laem Chabang, Thailand 2- off GE Frame 6B –GTE Water Wash System & Process vs. OEM Offline Only WW System
3. Evangeline, USA, 2-off Siemens 501F – GTE vs. OEM Online WW systemGTE Multi-Stage Water Wash System vs. OEM Online & Offline WW System
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Heat Rate Improvement: ~ 4-5%
Gross Power Improvement: ~ 8-10%
6xMS9001E GT Units Operating w/ 3 GTE 600i WW Systems
Case 1: GE MS9001E Paka Malaysia
Case 1: GE MS9001E Paka Malaysia
Operational Experience & Feedback • GT model: 6 off MS9001E, originally equipped with carbo-
blasting system for compressor blades cleaning
• Reported problems with oily contaminants, clogging of “instrumentation lines”, erosion of atomising air cooler tubes and risk of blocking the turbine blade cooling holes
• #6 GTE 600i-110 WW systems installation: May ’07 - June ‘08
• WW schedule: Offline every opportunity shutdowns with chemicalsOnline every day with Demi Water, no detergent
Feedback from customer• 45 MW recovery from all 6 GTs from the first offline wash
• Thermal efficiency has increased by 0.4% - 1.4%
• Average drop in the gross power output < 1 MW/month
• Improved gross HR can still be maintained up to 10 months
• Evaluation of gross power output recovery from subsequent offline washes for GT2A and GT2B indicates the recovery of approximately 1.5 MW and 2.0 MW respectively.
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BEFORE AFTER
Stage 1 & 2
Stage 17
Customer technical paper
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GTE performance recovery sustainable for up to 10 months vs. 3 with other systems
Case 1: GE MS9001E Paka Malaysia
Case 2: GE MS6001B Fortum Thailand
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15.2. 2.3. 17.3. 1.4. 16.4. 1.5. 16.5. 31.5. 15.6. 30.6. 15.7. 30.7. 14.8. 29.8. 13.9. 28.9. 13.10.
28.10.
12.11.
Gas T
urbin
e cor
recte
d out
put (
MW)
Installation of new GTE-400 system - Daily Online Water Wash +1.0% GT output deterioration without Online Washing System
Offline washes with OEM system Outage + Offline wash Offline wash
• Results +2.1% versus initial Offline with detergent 45 to 180 day Offline cycle +3% availability
52,000 hrs of service TD Online water providing +1.0% Production Output
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Application of Multi-Stage Compressor Cleaning System on Large Frame DLN Combustion Turbines
•GTE HP Bellmouth Nozzle & Manifold Install•GTE HP Cone Nozzle Install•Piping Upgrade
• HP Flanges•Zone manifold with valves• Water Cessation
Siemens Installation vs. GTE Installation
Siemens System
•Electrical Wiring•On-line CWW automation through WDPF•Logic Changes
• IGV’s• Fuel Fraction
GTE System
Installation Scope Summary
Siemens Water Wash Skid and GTE Module
GTE 1600iSiemens Skid
GTE System providing increased Radial & Circumferential Coverage
GTE Multi-Stage Nozzle Kit: Patent Pending
•GTE HP Cone Nozzle utilizing OEM Positions• OEM Manifold remains in place • GTE Nozzle direct replacement for OEM Nozzle
• Increased Flow Rate• Increased Radial Coverage • Characterized Droplet Size
•GTE HP Bellmouth Nozzle & Manifold Install•GTE Nozzle Placement in Velocity Field
• Increaded Flow Rate• Increased Radial Coverage • Characterized Droplet Size
• GTE Manifold for Bellmouth Nozzles • GTE Supply & Drain Valve Control
GTE Bellmouth Nozzle Installation
Bellmouth Nozzle Manifold SystemAlignment Procedure
GTE Coverage is Greatly Improved Over OEM
Siemens Online
Siemens On-crank GTE 2 Stage Offline
GTE 2 Stage Online
Coverage Comparison: Siemens vs. GTE
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GTE Coverage is Greatly Improved Over OEM
Coverage Comparison: Siemens vs. GTE
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GTE 3 Stage OnlineSiemens Online
GTE 3 Stage OfflineSiemens Offline
Siemens Water Wash GTE Water Wash
Droplet Size D[90] 250 microns D[90] = 150 micron
System Operating Pressure 200 psi 900 psi
Nozzle Pattern Full Cone Flat FanHeated Water No 140 °FTotal Flow Rate 24 GPM 42 GPM
Number of Nozzles 12 Cone12 Cone – Zone 18 Bellmouth – Zone 28 Bellmouth – Zone 3
System Differences: Siemens vs. GTE
Siemens SGT Water Wash
Daily Losses/ Degradation Rate: -.0317 MW/day
Start: 164.5 MW
Stop: 160.6 MW
ISO Corrected Power – Base Load Data
Case 3: Siemens 501F Cleco Evangeline US
Avg. Daily Degradation.0317 MW/day
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GTE Highly Atomized Water Wash System
Daily Losses/ Degradation Rate: -.01585 MW/day
Start: 162.0 MW
Stop: 160.6 MW
Avg. Daily Degradation.01585 MW/day
Corrected Power Summary
Exh Temp Unit 7-2 Unit 7-1 Net PercentRange Pwr Degr. Pwr Degr. Improvement Improvement
Temp Control -0.0317 -0.01585 0.0159 50.00%
ISO Corrected Power Daily Degredation Rates
Exh Temp Unit 7-2 Gross Pwr Unit 7-1 Gross PwrRange Start/Stop Loss Start/Stop Loss
Temp Control 164.5 162160.696 3.804 160.098 1.902 1.18%
Annual Benefit 3.59%
ISO Corrected Power Interpolated Losses
Percent Power Benefit
Case 3: Siemens 501F Cleco Evangeline US
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Siemens OEM Water Wash
Daily Losses/ Degradation Rate: +.5407 Btu/kWh/day
Start: 9080 Btu/kW-hr
Stop: 9144 Btu/kW-hr
ISO Corrected Heat Rate – Base Load Data
Case 3: Siemens 501F Cleco Evangeline US
Avg. Daily Degradation.5407 Btu/kw-hr
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GTE Water Wash
Daily Losses/ Degradation Rate: +.3164 Btu/kW-hr
Start: 9110 Btu/kW-hr
Stop: 9130 Btu/kW-hrAvg. Daily Degradation
.3164 Btu/kw-hr
Corrected Heat Rate Summary
Case 3: Siemens 501F Cleco Evangeline US
Exh Temp Unit 7-2 Unit 7-1 Net PercentRange HR Degr. HR Degr. Improvement Improvement
Temp Control 0.5407 0.3164 0.2243 41.48%
ISO Corrected Heat Rate Daily Degredation Rates
Exh Temp Unit 7-2 Gross Hr Unit 7-1 Gross HRRange Start/Stop Loss Start/Stop Loss
Temp Control 9080 91109144.884 -64.884 9136.916 -26.916 0.42%
Annual Benefit 1.27%
ISO Corrected Heat Rate Daily Degredation RatesPercent
HR Benefit
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Water Wash Product Offering
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Range (Mw)Up to 10 10 to 14 14 to 35 20 to 40 35 to 55 55 to 120 120 &
above Above 200
WW Product 50hz 30i 80i 160i 200i 400i 600i 1200i 1200i
WW Product 60hz 100i 200i 200i 400i 1000i 1600i 2200i
Specifications:• Stainless Steel Tank• Stainless or Carbon Steel Skid • PLC Control• Fully Automated Online CWW• Positive Displacement Delivery Pump • Adjustable Discharge Pressure• Automated Heater Control & Protection• Automated Level Control & Protection• Discharge Fluid Filtration
Eco Value ™Water Wash
Options:• Adjustable Detergent Flow Control• User Interface Panel (HMI), touch-screen• Electric Detergent Drum Pump• Total Dissolved Solids feedback & control• Automated Detergent Injection (Optional)• Remote Operation (Optional)
• Data Logging (Optional)
Track Record• > 1000 Turbines• > 30M Operating Hours• Validated Results
Benefits/Demonstrated Improvement• Availability: ~ 2 % • Performance/Output: ~ 3 % • Heat Rate: ~ 1 %• Payback < 6
Months
Long Term OEM Agreements• Siemens• Caterpillar / Solar• Rolls Royce• GE Aero
Business Overview and History
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Conclusions: GTE Overall Product Portfolio
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Eco Value™Water Wash
Fluid Systems
Control Panels
Aux Skids
Advanced FuelSkids
Power Aug
CombustionProducts
ECOMAX™ DLN Tuning Products
Dynamics Monitoring and Services
Combustion DLN 2 Repair & New
Combustion DLN 1 Repair & New
Developing Integrated Product & Service Solutions
Turbine Services
Business Overview and History
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• Gas Turbine Efficiency PLC – Established in 1989– Aviation and Industrial Water Wash
– Eastern Hemisphere HQ in Sweden
• IPO on London AIM Exchange in December 05– Strengthened Leadership Team - Industrial
• Established Manufacturing Capabilities in US– Control Center LLC in Orlando, FL Western Hemisphere HQ since 2007
• Established Combustion Repair Capability and Facilities in US– Duncan, SC Combustion Repair acquired in June 2007
• Enhanced Combustion and Fuel Systems Capabilities– Addition of Combustion Design team in Troy, NY
• Establishing Sales and Service Capabilities Worldwide – Recent addition of North Lincolnshire, UK and Florence, Italy
– Business Development & Sales Office, Dubai & Abu Dhabi UAE
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GTE… in Summary
Thank you!
World Class Leadership Team
Proven Technical Expertise
Responsive, Agile, Accessible
Extensive Knowledge of CombustionTurbines and Oil & Gas Industry
– Specializing in Combustion, Fuel Management and Auxiliary systems