Gas Turbine Training Power Point -Sample

Presented by Ali Rafiee

Demo Version of Gas Turbine TrainingPower PlantPower Plant

1

Evolution of the Gas Turbine

As early as 1791, John Barber’s patent for the steam turbine described other fluidst ti lor gases as potential energy sources.

In 1808 John Dumball envisioned a multi-stage turbine. Unfortunately his ideaconsisted only of moving blades without stationary airfoils to turn the flow into eachconsisted only of moving blades without stationary airfoils to turn the flow into eachsucceeding stage.

Not until 1872 did Dr. Franz Stolze combine the ideas of Barber and Dumball toNot until 1872 did Dr. Franz Stolze combine the ideas of Barber and Dumball todevelop the first axial compressor driven by an axial turbine.1 Due to a lack offunds, he did not build his machine until 1900.

In 1905, the first gas turbine and compressorunit built by Brown Boveri was installed (20 kilowatt).

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Oil And Gas Turbomachinery Applications

Turbomachinery ApplicationsApplications

Upstream Midstream Downstream


Efficiency of Fossil-fired Power Plants

N t Effi i [%]

50

60Net Efficiency [%]

Combined cycleCombined cycle

40Diesel EnginesDiesel Engines

Combined cyclegas and steamturbines

Combined cyclegas and steamturbines

20

30

Coal‐firedSteam Power Plants

Coal‐firedSteam Power Plants

Heavy industrial natural gas‐fired turbine, simplecycle

Heavy industrial natural gas‐fired turbine, simplecycleBiomass firedBiomass fired

0

10

cyclecycleBiomass‐firedSteamPower PlantsBiomass‐firedSteamPower Plants

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1 2 200 1000 200010 20 100Maximum single unit output [MW]

4

Aero-Derivative and Heavy Industrial

In spite of their common background, there are variations between the aero‐derivative and heavy industrial gas turbines

The most obvious difference is in the physical size of the heavy industrial compared to the aero‐derivative gas turbines

and heavy industrial gas turbines.

Ob i I d i l C d T A D i i

the aero derivative gas turbines.

Observation Industrial Compared To Aero‐Derivative

Shaft speed slower

Air flow higher

Maintenance time longer

Maintenance lay‐down space larger


Air Inlet System


Consequences of Poor Inlet Filtration

Foreign Object Damage Erosion Fouling Cooling Passage Plugging

Foreign Object Damage

Particle Fusion Corrosion

Erosion


STG600 Air intake system


Air Inlet System


Air Inlet System : (Evaporative Cooler)


SGT600 Compressor Casing

The compressor casing, covering the whole compressor section, is horizontally split to facilitate maintenance.

The casing contains the three stator subassemblies front, central and rear stator casings.

These casings carry the guide vanes and the stator irings.

The stator casings form slots for bleeding air downstream the second (LP bleed) and the fifth stage (HP bleed)stage (HP bleed).


Velocity Triangle for one Stage


CCompressor


Compressor curves

Design Point

Surge Line

atio

Efficiency Lines

Choke Line

Pressur

e Ra

Choke Line

Mass flow


SGT600 compressor


Compressor Water Washing System

REDUCTION OF OUTPUT AND EFFICIENCY

THROUGH COMPRESSOR SOILING AND AGING


SGT-600 BV and IGV function


Combustion Chambers Type

Can or Tubular

Burner Type Annular

Can‐annular


SGT600 Combustion Chamber


Combustion ChamberCombustion Chamber

Model V94.2Two vertical silo ‐ typecombustion chamberseach with 8 burners

Model V94.3Two horizontally opposed combustionchambers each with 8 burners

2.20 m

Flamecylinder

3.80 m

Model V94.3A Hybrid‐Burner‐Ring (HBR) Combustion ChamberOne annular combustor with 24 burners

2.20 m


3.50 m

20

Combustion ChamberCombustion Chamber


Axial Turbine Velocity Triangle


Turbine


Turbine


Exhaust


Turbocompressor Components And Layout

Main Equipmentq p

Inside the Package

Outside the Package

• Fuel system and spark igniter• Natural gas (control valves)• Liquid (pumps, valves)

• Bearing lube oil system

• Enclosure and fire protection system• Inlet system

• Air-filter (self-cleaning, barrier, inertial, demister, screen)

• Tank (overhead, integral)• Filter (simple, duplex)• Pumps (main, pre/post, backup)

• Accessory gear• Fire/gas detection system

• Silencer•Exhaust system

• Silencer• Stack• Fire/gas detection system

• Starter/helper drive• Pneumatic, hydraulic, variable speed alternating current (AC) motor

• Controls and instrumentation (on-skid, off-skid)

• Lube oil cooler (water, air)• Fuel filter/control valve skid• Motor control center• Switchgear, neutral ground resistor


Controls and instrumentation (on skid, off skid)• Seal gas/oil system (compressors) • Inlet fogger/cooler

Lubrication System

Primary Purposes of a Lubrication System :

Reduces Friction Cushions Cools Cleans Seals


Thrust Bearing Position Monitoring

Thi i lifi d d i h dd t This simplified drawing shows an eddy‐current transducer mounted to one of the thrust pads and observing the thrust collar, so that it can measure the thickness of the lubricating oil film between ththem.


Thrust Bearing Collar

30 microns

120 ‐200

This diagram shows the mutual positioning of thrust bearing pads relative to the

This plot shows variations in measured oil film thickness across the surface of a thrust of thrust bearing pads relative to the

supported thrust collar. Note: The angle of the thrust pads is highly exaggerated for clarity.

film thickness across the surface of a thrust bearing pad in a running machine. Darker shading represents largest film thickness, while lighter shading represents smallest thickness


thickness.

Labyrinth Seal


Fuel gas Supply


SGT600 Ignition gas system

Shut off valve

Control valve (needle type)OrificeSafety valve

Shut off valve(Burner 6)

Shut‐off valve (Spring closing type)


Pressure reducing valve Bypass valve Three‐way shut‐off valve

System Operating :Start-Up Sequence


SGT600 Starter motor system


Gas Turbine Control Modes:

In part load we have 3 different control mode:

air fuelIGV = constant M = constant M = variable

air fuel

air fuelTET = constant M = variable M = vari

TIT = constant M = variable M = variab

able

le


Gas Turbine Control Modes: Sample

IGV fix TET fix TIT fix

600

650

)

500

550

mas

s flo

w(k

g/se

c)

400

450

Com

pres

sor a

ir m

300

350

0 5 0 55 0 6 0 65 0 7 0 75 0 8 0 85 0 9 0 95 1


0.5 0.55 0.6 0.65 0.7 0.75 0.8 0.85 0.9 0.95 1

GT load/full load

36

SGT-600 Industrial Gas Turbine

Efficiency Vs. Inlet Filter Pressure Loss34 0

Inlet Filter Pressure Loss

Efficiency

33.8

34.0

=33.6

c ef

f [%

]

1 mbar 0.025 % 33.4

lant

gro

ss e

lec

33 0

33.2

Pl


0 10 20 30 4033.0

Inlet filter pressure loss [millibar]

37

What is API?

American Petroleum Institute (API):US P l I d P i T d A i i US Petroleum Industry Primary Trade Association

400 Member Companies Covers all Aspects of Oil & Gas Industry Accredited by ANSI (American National Standards Organization) Accredited by ANSI (American National Standards Organization) Started Developing Standards in 1924 Maintains about 500 Standards

API Specifications Typically LagPhilosophy:

Improve Safety Improve Environmental Performance

API Specifications Typically LagTechnology Developments!

Reduce Engineering Costs Improve Equipment Interchangeability Improve Product Quality Lower Equipment Cost


Lower Equipment Cost Allows for Exceptions for Reason

38

API 616 code

1. Scope (and alternative designs)2. References (more or less everything is referenced)( y g )3. Definitions

ISO rating, normal operating point, maximum continuous speed, trip speed, etc. Note: Some basic requirements are hidden here (e.g. MCS)

4. Basic Design P ti t d i b i / l b l i i t t i l l b i ti Pressure ratings, rotordynamics, bearings/ seals, balancing requirements, materials, lubrication

Covers quality and mechanical integrity issues Primarily core engine

5. Accessories Starters, inlet/ exhaust, mounting, fuel, gears, enclosures, fire protection, tools, , g, , g , , p , Mostly on-skid package items

6. Inspection, Testing, and Preparation for Shipment Required and optional tests: hydrostatic, mechanical run, package, PTC 22 Long term and short term shipping

Mi i l t t i t Minimal test requirements 7. Vendor Data

Drawings, performance data, calculations, quality documentation References, Appendix B list.

8. Appendix


pp A. Data sheets B. Vendor drawing and data requirements C. Procedure to determine residual unbalance

(balancing) D. Lateral and torsional logic diagrams E. Gas turbine nomenclature

39

API 616 code : Basic Design


API 616 code

4.8—Bearings: applies to all gas turbine bearings. 4 8 1 1—Hydrodynamic radial and thrust bearings are preferred These should be thrust-4.8.1.1 Hydrodynamic radial and thrust bearings are preferred. These should be thrust

tilt pad, radial-tilt pad, or sleeve bearings. 4.8.2.5—If rolling element bearings are used they must meet 50,000 hours of continuous

operation. Few industrial gas turbines utilize rolling element bearings and aeroderivativeengines are not applicable to API 616 (1998).

4.8.3.3—The bearing shells shall be horizontally split. Many original equipment manufacturers (OEMs) take exception to this requirement.

4.8.4.2—Hydrodynamic thrust bearings shall be selected at no more than 50 percent of the ultimate load rating at site power. This requirement should not be taken exception to.4 8 5 2 B i h i R l bl l b i h b ff l i d L l 4.8.5.2—Bearing housings: Replaceable labyrinth type buffer seal required. Lip-seals are not acceptable—this cannot be met by some manufacturers.

Replaceable labyrinth


Lip‐seals

API Datasheet

Forms technical basis of proposal

Define Customer Site, Operating, and Equipment Minimum Requirements

Most important technical contractual document

Must always be filled out:

•API 616 Appendix A & B (Gas Turbine)API 614 A di D (L b Oil S )•API 614 Appendix D (Lube Oil System)

•API 670 Appendix A (Machinery Protection)

When filling out the API Data Sheets :

• Read all the notes: Some critical requirements are often hidden here.

• Fill out as much info as is available: Even partially


Fill out as much info as is available: Even partially filled out sheet is better than no sheet.

API Datasheet

By Purchaser

By ManufacturerBy Manufacturer

By ManufacturerBy Manufacturerif not by Purchaser


Note: API 616 does not apply to Aero-Derivative Gas Turbines – Only Industrial!

Technical Bid Evaluation Guidelines

3. Decide the best type Aero derivative or Heavy Duty:H D / I d i l T H C i M i iff h f i i h j l b i1. Heavy Duty / Industrial Type: Heavy Casing, Massive stiff shafting with journal bearing, requires pre-post lube, cheap but excessive lube, less frequent maintenance.

2. Aero derivative: Light Casing, Rotor shafting is 2 or more shaft, Each with its own bearing, Expensive but less lube (aero type), Higher efficiency but very rapid decrease after washing, Quick overhaul

4. Evaluate Efficiency, performance and loss update process calculation:1 Effi i 30% 70% f t ti l d d i i d t d i i1. Efficiency 30% means 70% of rotational energy produced is required to drive air

compressor in order to maintain sufficient air flow for combustion.2. Evaluate Performance and Loss3. Fuel Type: In the case of Dual fuel that is liquid hotter and less efficiency than gas, yp q y g

Engine efficiency liquid 1.3% lower.4. Heat Rate: amount of heat energy to produce output5. Inlet Loss: P drops through inlet filters6 E h t L P d th h t k il WHR (b th t thi ill t


6. Exhaust Loss: P drops through stack, silencer, WHR (be aware that this will create backpressure)

44

Factory Performance Tests

Full speed, full load test for four hours Typically against a water break or generator/load cells Determines maximum output power, specific fuel consumption, and efficiency


Start-Up or Shutdown Control Loops


Start up sequence


Protective System


VIBRATION


Protective Systems

Most gas turbines are protected against the following:

Low lube oil pressure High vibrationg Turbine overspeed High lube oil temperature Exhaust temperature Exhaust temperature Blade path temperature High acceleration. High thrust pad temperature Low or high gas turbine inlet vacuum High turbine exhaust pressure


g p

50

Failure Diagnostics

Combustor Analysis

The measured parameters in the combustors are pressure of the fuel and evenness of combustion noise. The inlet temperature to the turbine is not normally measured due to the very high temperatures in the combustors.


Table above shows how some problems affect the various parameters of the compressor.

51

Calculation of Equivalent Operating Hours

tequ = a1 x n1 + a2 x n2 + ti + f x w x (b1 x t1 + b2 x t2)n

i=1

f = Fuel weighting factor w = Weighting factor for water/steam

injectiont1 = Operating hours at power settings up to

base loadb1 = 1 (weighting factor for base‐load duty)t2 = Operating hours for power settings

above base load (peak load)b2 = 4 (weighting factor for peak‐load duty)


SGT-600 Maintenance Plan


Loading/Unloading Capability of V94.2

1 Fuel stop valve opens2 Frequency converter off

3 Excitation on4 Synchronization

Speed120

PGT (ISO)

4 MW/minSpeedRPM

3000

80

100

% Peak loadBase load

4

30 MW/min

11 MW/min

4 MW/min

2000

100040

60

Normal loading

11 MW/min

1

1000

00 1 2 3 4 0 2 4 6 8 10 12 14 0 2 4 6 8 10 12 14 16

0

20

20 MW

g

and unloading


0 1 2 3 4 0 2 4 6 8 10 12 14 0 2 4 6 8 10 12 14 16min.unloading Time

min.loading Time

min.Start‐up Time

54

Electricity Generation Costs, Without Emission Trading


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Gas Turbine Training Power Point -Sample