Gas Turbine Training Power Point -Sample
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The document provides an overview of gas turbine evolution and components. It discusses the development of axial compressors and turbines from the 18th century ideas of John Barber and John Dumball. It then summarizes the key components of modern gas turbines, including compressors, combustion chambers, turbines, lubrication systems, and controls. Examples are given for Siemens SGT600 components like the compressor, combustion chamber, and control modes.
![Efficiency of Fossil-fired Power Plants
N tEffi i [%]
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NetEfficiency[%]
CombinedcycleCombinedcycle
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DieselEnginesDieselEngines
Combinedcycle
gasandsteam
turbines
Combinedcycle
gasandsteam
turbines
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30
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SteamPower
Plants
Coal‐fired
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Heavyindustrial
naturalgas‐fired
turbine,simple
cycle
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naturalgas‐fired
turbine,simple
cycleBiomass firedBiomass fired
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SteamPowerPlants
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Rafiee.ali@gmail.com GasTurbineTrainingCourse
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4](https://image.slidesharecdn.com/8661d471-b1a4-47b6-acaa-70795a70e334-150716122132-lva1-app6892/85/Gas-Turbine-Training-Power-Point-Sample-4-320.jpg)
![SGT-600 Industrial Gas Turbine
EfficiencyVs.InletFilterPressureLoss
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Efficiency
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Rafiee.ali@gmail.com GasTurbineTrainingCourse
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Gas Turbine Training Power Point -Sample
- 1. Presented by Ali Rafiee Demo Version of Gas Turbine Training Power PlantPower Plant 1
- 2. Evolution of the Gas Turbine As early as 1791, John Barber’s patent for the steam turbine described other fluids t ti lor gases as potential energy sources. In 1808 John Dumball envisioned a multi-stage turbine. Unfortunately his idea consisted 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 each succeeding 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 to develop the first axial compressor driven by an axial turbine.1 Due to a lack of funds, he did not build his machine until 1900. In 1905, the first gas turbine and compressor unit built by Brown Boveri was installed (20 kilowatt). Rafiee.ali@gmail.com GasTurbineTrainingCourse 2
- 3. Oil And Gas Turbomachinery Applications Turbomachinery ApplicationsApplications Upstream Midstream Downstream Rafiee.ali@gmail.com GasTurbineTrainingCourse 3
- 4. Efficiency of Fossil-fired Power Plants N tEffi i [%] 50 60 NetEfficiency[%] CombinedcycleCombinedcycle 40 DieselEnginesDieselEngines Combinedcycle gasandsteam turbines Combinedcycle gasandsteam turbines 20 30 Coal‐fired SteamPower Plants Coal‐fired SteamPower Plants Heavyindustrial naturalgas‐fired turbine,simple cycle Heavyindustrial naturalgas‐fired turbine,simple cycleBiomass firedBiomass fired 0 10 cyclecycleBiomass‐fired SteamPowerPlants Biomass‐fired SteamPowerPlants Rafiee.ali@gmail.com GasTurbineTrainingCourse 1 2 200 1000 200010 20 100 Maximumsingleunitoutput[MW] 4
- 5. Aero-Derivative and Heavy Industrial Inspiteoftheircommonbackground,therearevariationsbetweentheaero‐derivative andheavyindustrialgasturbines Themostobviousdifferenceisinthephysicalsizeoftheheavyindustrialcomparedto theaero‐derivativegasturbines andheavyindustrialgasturbines. Ob i I d i lC dT A D i i theaero derivativegasturbines. Observation IndustrialComparedToAero‐Derivative Shaftspeed slower Airflow higher Maintenancetime longer Maintenancelay‐downspace larger Rafiee.ali@gmail.com GasTurbineTrainingCourse 5
- 6. Air Inlet System Rafiee.ali@gmail.com GasTurbineTrainingCourse 6
- 7. Consequences of Poor Inlet Filtration Foreign Object Damage Erosion Fouling Cooling Passage Plugging ForeignObjectDamage Particle Fusion Corrosion Erosion Rafiee.ali@gmail.com GasTurbineTrainingCourse 7
- 8. STG600 Air intake system Rafiee.ali@gmail.com GasTurbineTrainingCourse 8
- 9. Air Inlet System Rafiee.ali@gmail.com GasTurbineTrainingCourse 9
- 10. Air Inlet System : (Evaporative Cooler) Rafiee.ali@gmail.com GasTurbineTrainingCourse 10
- 11. 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). Rafiee.ali@gmail.com GasTurbineTrainingCourse 11
- 12. Velocity Triangle for one Stage Rafiee.ali@gmail.com GasTurbineTrainingCourse 12
- 16. Compressor Water Washing System REDUCTIONOFOUTPUT ANDEFFICIENCY THROUGHCOMPRESSOR SOILINGANDAGING Rafiee.ali@gmail.com GasTurbineTrainingCourse 16
- 17. SGT-600 BV and IGV function Rafiee.ali@gmail.com GasTurbineTrainingCourse 17
- 18. Combustion Chambers Type CanorTubular BurnerType Annular Can‐annular Rafiee.ali@gmail.com GasTurbineTrainingCourse 18
- 19. SGT600 Combustion Chamber Rafiee.ali@gmail.com GasTurbineTrainingCourse 19
- 20. Combustion ChamberCombustion Chamber Model V94.2 Twoverticalsilo‐ type combustionchambers eachwith8burners ModelV94.3 Twohorizontallyopposedcombustion chamberseachwith8burners 2.20mFlame cylinder 3.80m ModelV94.3A Hybrid‐Burner‐Ring(HBR)CombustionChamber Oneannularcombustorwith24burners 2.20m Rafiee.ali@gmail.com GasTurbineTrainingCourse 3.50m 20
- 21. Combustion ChamberCombustion Chamber Rafiee.ali@gmail.com GasTurbineTrainingCourse 21
- 22. Axial Turbine Velocity Triangle Rafiee.ali@gmail.com GasTurbineTrainingCourse 22
- 26. Turbocompressor Components And Layout Main Equipmentq p Insidethe Package Outsidethe 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 Rafiee.ali@gmail.com GasTurbineTrainingCourse 26 Controls and instrumentation (on skid, off skid) • Seal gas/oil system (compressors) • Inlet fogger/cooler
- 27. Lubrication System Primary Purposes of a Lubrication System : Reduces Friction Cushions Cools Cleans Seals Rafiee.ali@gmail.com GasTurbineTrainingCourse 27
- 28. Thrust Bearing Position Monitoring Thi i lifi d d i h dd tThis simplified drawing shows an eddy‐current transducermountedtooneofthethrustpadsand observingthethrustcollar,sothatitcanmeasure thethicknessofthelubricatingoilfilmbetween ththem. Rafiee.ali@gmail.com GasTurbineTrainingCourse 28
- 29. Thrust Bearing Collar 30microns 120‐200 Thisdiagramshowsthemutualpositioning of thrust bearing pads relative to the Thisplotshowsvariationsinmeasuredoil filmthicknessacrossthesurfaceofathrust of thrust bearing pads relative to the supported thrust collar. Note: The angle of the thrust pads is highly exaggerated for clarity. filmthicknessacrossthesurfaceofathrust bearingpadinarunningmachine.Darker shadingrepresentslargestfilmthickness, whilelightershadingrepresentssmallest thickness Rafiee.ali@gmail.com GasTurbineTrainingCourse 29 thickness.
- 31. Fuel gas Supply Rafiee.ali@gmail.com GasTurbineTrainingCourse 31
- 32. SGT600 Ignition gas system Shutoffvalve Controlvalve (needletype)Orifice Safetyvalve Shutoffvalve (Burner6) Shut‐offvalve (Springclosingtype) Rafiee.ali@gmail.com GasTurbineTrainingCourse 32 Pressurereducingvalve Bypassvalve Three‐wayshut‐offvalve
- 33. System Operating :Start-Up Sequence Rafiee.ali@gmail.com GasTurbineTrainingCourse 33
- 34. SGT600 Starter motor system Rafiee.ali@gmail.com GasTurbineTrainingCourse 34
- 35. 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 Rafiee.ali@gmail.com GasTurbineTrainingCourse 35
- 36. Gas Turbine Control Modes: Sample IGV fix TET fix TIT fix 600 650 ) 500 550 massflow(kg/sec) 400 450 Compressorairm 300 350 0 5 0 55 0 6 0 65 0 7 0 75 0 8 0 85 0 9 0 95 1 Rafiee.ali@gmail.com GasTurbineTrainingCourse 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
- 37. SGT-600 Industrial Gas Turbine EfficiencyVs.InletFilterPressureLoss 34 0 InletFilter PressureLoss Efficiency 33.8 34.0 =33.6 ceff[%] 1 mbar 0.025 % 33.4 lantgrosselec 33 0 33.2 Pl Rafiee.ali@gmail.com GasTurbineTrainingCourse 0 10 20 30 40 33.0 Inlet filter pressure loss [millibar] 37
- 38. 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 APISpecificationsTypicallyLag Philosophy: Improve Safety Improve Environmental Performance APISpecificationsTypicallyLag TechnologyDevelopments! Reduce Engineering Costs Improve Equipment Interchangeability Improve Product Quality Lower Equipment Cost Rafiee.ali@gmail.com GasTurbineTrainingCourse Lower Equipment Cost Allows for Exceptions for Reason 38
- 39. 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 Rafiee.ali@gmail.com GasTurbineTrainingCourse 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
- 40. API 616 code : Basic Design Rafiee.ali@gmail.com GasTurbineTrainingCourse 40
- 41. 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 aeroderivative engines 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. Replaceablelabyrinth Rafiee.ali@gmail.com GasTurbineTrainingCourse 41 Lip‐seals
- 42. 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 Rafiee.ali@gmail.com GasTurbineTrainingCourse 42 Fill out as much info as is available: Even partially filled out sheet is better than no sheet.
- 43. API Datasheet ByPurchaser ByManufacturerByManufacturer ByManufacturerByManufacturer ifnotbyPurchaser Rafiee.ali@gmail.com GasTurbineTrainingCourse 43 Note: API 616 does not apply to Aero-Derivative Gas Turbines – Only Industrial!
- 44. 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 Loss 3. 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 output 5. Inlet Loss: P drops through inlet filters 6 E h t L P d th h t k il WHR (b th t thi ill t Rafiee.ali@gmail.com GasTurbineTrainingCourse 6. Exhaust Loss: P drops through stack, silencer, WHR (be aware that this will create backpressure) 44
- 45. 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 Rafiee.ali@gmail.com GasTurbineTrainingCourse 45
- 46. Start-Up or Shutdown Control Loops Rafiee.ali@gmail.com GasTurbineTrainingCourse 46
- 47. Start up sequence Rafiee.ali@gmail.com GasTurbineTrainingCourse 47
- 50. 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 Rafiee.ali@gmail.com GasTurbineTrainingCourse g p 50
- 51. 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. Rafiee.ali@gmail.com GasTurbineTrainingCourse Tableaboveshowshowsomeproblemsaffectthevariousparametersofthecompressor. 51
- 52. Calculation of Equivalent Operating Hours tequ =a1 xn1 +a2 xn2 + ti +fxwx(b1 xt1 +b2 xt2) n i=1 f = Fuelweightingfactor w = Weightingfactorforwater/steam injection t1 = Operatinghoursatpowersettingsupto baseload b1 = 1(weightingfactorforbase‐loadduty) t2 = Operatinghoursforpowersettings abovebaseload(peakload) b2 = 4(weightingfactorforpeak‐loadduty) Rafiee.ali@gmail.com GasTurbineTrainingCourse 52
- 53. SGT-600 Maintenance Plan Rafiee.ali@gmail.com GasTurbineTrainingCourse 53
- 54. Loading/Unloading Capability of V94.2 1Fuelstopvalveopens 2Frequencyconverteroff 3Excitationon 4Synchronization Speed 120 PGT (ISO) 4MW/min Speed RPM 3000 80 100 % Peakload Baseload 4 30MW/min 11MW/min 4MW/min 2000 1000 40 60 Normalloading 11MW/min 1 1000 0 0 1 2 3 4 0 2 4 6 8 10 12 14 0 2 4 6 8 10 12 14 16 0 20 20MW g andunloading Rafiee.ali@gmail.com GasTurbineTrainingCourse 0 1 2 3 4 0 2 4 6 8 10 12 14 0 2 4 6 8 10 12 14 16 min. unloadingTime min. loadingTime min. Start‐upTime 54
- 55. Electricity Generation Costs, Without Emission Trading Rafiee.ali@gmail.com GasTurbineTrainingCourse 55
- 56. THANK YOU FOR YOUR PATIENCE Rafiee.ali@gmail.com GasTurbineTrainingCourse END 56