GAS TURBINES IN SIMPLE CYCLE COMBINED CYCLE APPLICATIONS

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GAS TURBINES IN SIMPLE CYCLE COMBINED CYCLE APPLICATIONS ( gas-turbines-in-simple-cycle-combined-cycle-applications )

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46 • High speed response of less than 60 ms required by aeroderivative gas turbines to prevent overspeed in block off-load conditions. • Explosion proof actuation to appropriate specification standards, allows operation in hazardous methane service. • Resistance to fuel contaminants including tar, shale, water, sand and so forth. • 24 volts DC is the maximum drive voltage which ensures personnel safety • Corrosion resistance in components exposed to wet fuel and corrosion resistance to all parts if the service is sour gas. Other operational objectives that dictate design features are operator’s requirements for: • Low mean time to repair (LMTR). The target of 1 hour, achieved with modular design, together with the target MTBF provided an availability of 99.998% for HSDE’s original stepper. • Higher Mean time between failures (MTBF). In HSDE’s case, a target of 50,000 hours was set and achieved. • Low maintenance costs, since the modular design can be repaired by an individual with relatively low expertise. Service intervals are 12 months. • Large control ratio which allows control over the ignition to full load as well as full speed ranges to be possible with one fuel valve. Fuel pressure variation compensation is provided. The additional speed ratio type control valve found in many other industrial gas fuelled installations is not required here. • Low power consumption since an electric motor of less than 100 watts is used. This also eliminates the need for additional hydraulic or pneumatic systems. Also black starting is more reliable if the fuel system is powered by the same batteries as the controller. PCS applications experience with fast response valves: Power production in Phase II of the Petroleum Corporation of Singapore or PCS, was commissioned in June 1997. PCS is part of a massive petrochemical plastics conglomerate in Singapore. Power production was an afterthought, as when they were built, their design did not include provision for them becoming an SPP. PCS chose a nominally 25 MW (23 MW in their normal ambient conditions) ABB GT10, although their power needs are roughly 26MW. This was because while SP were pleased to sell them their residual requirement; they would not buy any power from SPPs at the time of original power plant design. The turbine is fuelled by three different types of fuel, depending on the state of the plant. The BTU for each type varies, so again the fast response time for the stepper valve is critical. As PCS operations found, their fast response valve proved as useful as the stepper valve has been for power generation on the North Sea oil and gas platforms. The fast response time of the Moog (and other stepper valve manufacturers’) design helps the valve avoid the sudden burst of excess temperatures that accompany higher heating value fuel. (North Sea platform users frequently operate gas, liquid or gas & liquid fuel mixtures). Not all gas turbines are tolerant of a wide range of fuel types in a single application. Some of them require a whole different fuel system - nozzles, lines and all components - to be able to handle a totally different heating value fuel. In this application in Singapore, the ABB machine shows no sign of distress, which is interesting since the heating value of the fuel types varies as much as 50 percent. The exact fuel composition data is proprietary to PCS. PCS’s GT10 heat recovery steam generator (HRSG) provides a reliable source of steam. The plant exports steam to the nearby Seraya Chemicals plant in addition to fulfilling their needs. Emissions and steam supply: The original ABB EV burner design - a low NOx burner which can be fitted and retrofitted on the GT10, fuel types permitting - was not fitted in this case. The EV burner will handle clean natural gas and clean diesel fuel. It was not suitable for the high hydrogen content and variations in fuel composition that this application involves. Such fuels need a more forgiving fuel system, as well as water or steam injection to keep the NOx down. The PCS Singapore application uses steam for NOx reduction purposes. The steam is piped in through nozzles that are adjacent to the fuel nozzles on the fuel manifold of the GT10’s annular combustor. The source of the steam is the heat recovery steam generator (HRSG) that is packaged as part of the GT-10 system. If and when required, the plant also can draw high pressure steam from their process cracker. In PCS’ case, one boiler has been found to suffice. This is noteworthy as in applications like this, a redundant “packaged boiler” (running hot and on minimum load) is often found essential. This is so that it is possible to pick up the steam load should the turbine trip or be unavailable due to maintenance. A common subject for debate is whether uninterrupted steam supply during the switch from HRSG mode to fresh air firing is possible without flame out on the boiler supplementary burners.

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