GAS TURBINE & RECIPROCATING ENGINE
DECISIONS UPDATE
November 13, 2016
McIlvaine Company
TABLE OF
CONTENTS
Trump
moving forward to Dismantle Greenhouse Gas Regulations
Participate in the LinkedIn Discussion Groups
Lubrication is Key to Successful Gas Turbine Operations
Recent
Additions to Intelligence System
Pleasant Valley Station solves ultrapure water testing
problem
Total Iron Measurement in Ultrapure Water is Critical
Instrument Air Pressure Problem solved at South
Carolina Electric and Gas Co
Clarke Energy connecting more than 700 Sites to GE’s
Myplant Asset Performance Management Program
GE developing Digital Monitoring Technology in Saudi
Arabia
Trump has already vowed to “cancel” last year’s Paris
climate agreement, which commits more than 190 countries to reduce their
emissions of planet-warming carbon dioxide pollution, and to dismantle the Clean
Power Plan. He has named Myron Ebell of the business-backed Competitive
Enterprise Institute to head his EPA transition team. Mr. Ebell has asserted
that whatever warming caused by greenhouse gas pollution is modest and could be
beneficial.
The Clean Power Plan is the ambitious centerpiece of
President Obama’s climate change legacy and the key to his commitment under the
Paris Accord. At its heart is a set of Environmental Protection Agency
regulations intended to curb planet-warming pollution from coal-fired power
plants. If enacted, the rules could transform the American electricity sector,
close hundreds of coal-fired power plants and usher in the construction of vast
new wind and solar farms. The plan is projected to cut United States power plant
emissions 32 percent from 2005 levels by 2030.
But the program is currently under litigation by 28 states
and more than 100 companies, and it is expected to go before the Supreme Court
as early as next year.
As a subscriber to
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Power plant
high performance pumps
Analysis of hardware and treatment options to create
ultrapure water for steam generation and then to purify and move the recycled
condensate. Options for filtration, ion removal, valves, pumps, instruments and
chemicals are included.
Is ion exchange or
electodeionization the best selection?
This question also needs to take into account the process
arrangement, the use of membranes for particle removal and even whether membrane
degasification is incorporated. The consumables and maintenance with ion
exchange are also important.
Evoqua in a 59De posted article says new developments in
CEDI module construction have improved both physical integrity and module
reliability while simultaneously enabling process simplification such as
elimination of concentrate recirculation and elimination of salt injection into
the concentrate stream. However, reliable long-term operation of an RO/CEDI
system requires careful attention to process design, and in particular hardness
and chlorine. With good module and system design, it is possible to design
deionized water systems based on reverse osmosis/CEDI that will consistently
meet the makeup water quality requirements of high pressure boilers without the
use of hazardous chemicals and without creating regenerate waste.
How is the best way
to remove natural organic matter?
Robert McIlvaine, Ovivo provide their answer in a McIlvaine
webinar which is recorded and available in PPAQD.
Each process step has specific reduction rates for each NOM
family:
The varied types of power generation equipment found around
the world place many varying demands upon industrial gear oils. From hydro-power
generation, through conventional steam and gas turbines through to modern wind
turbine generators, industrial gear oils need to have excellent, robust and
reliable performance. When it comes to turbines – gas, steam or combined cycle –
and circulating oil systems, lubricants play the key role in high-performance
operation. These systems must provide a great deal of power in often harsh
environments. As a result, they require quality fluid packages that will provide
the anti-wear, anti-corrosion and extreme pressure protection that will ensure
optimum performance.
Lubrizol supplies additives and packages for turbine and
circulating oil systems. Products are designed to provide peak system
performance, with benefits that include:
•
Excellent demulsibility
•
Superior foam protection
•
Excellent rust protection
•
Low copper activity
•
Good oxidation stability
•
Superior wet and dry filterability
•
Outstanding hydrolytic stability
•
Excellent modified rotary bomb performance
•
Very good EP/anti-wear performance
•
Good seal compatibility
Lubrizol® 5810 is a mainline turbine oil
additive system designed for steam and medium duty gas turbines with several
benefits:
Corzan® HP industrial piping system is claimed
to increase operational efficiency, minimize downtime and improve bottom-line
performance.
These piping systems are supplied by Lubrizol, a Berkshire
Hathaway Company.
Here are the summaries and links to the full articles which
have recently been added to GTRE Decisions Intelligence System.
Wastewater
permit for coal and combustion turbine plants in Gillette Wyoming
This 2015
permit authorizes the discharge of wastewater from six coal fired power plants,
two combustion turbine power plants, and one coal mine. The Neil Simpson and
Wygen generating power plants and the coal mine are located approximately six
miles east of Gillette, Wyoming. Most of the wastewater generated by the
facility is recycled, so this facility rarely discharges. Discharges usually
occur in response to large storm events. Note below that the facilities are
air-cooled, so they do not discharge cooling water. Therefore, 316(b)
regulations do not apply. In addition, make-up water is partially treated water
from the Gillette wastewater treatment plant, not waters of the Wastewater
originating from the variety of sources is routed to a two cell settling pond.
The first pond, called the Bottom Ash Settling Pond, functions to provide
settlement for sediments and ash by-products. Wastewater from this pond
overflows to the second pond called the Clear Pond. The Clear Pond has an outlet
structure (Outfall 001) that allows the discharge of the treated wastewater to
Donkey Creek. However, because a majority of the wastewater that enters the
settling ponds is recycled, there is seldom a discharge to the creek.
Revision Date:
11/7/2016
Tags:
BHE Environmental, Inc., Regulation, Wastewater
2014 BHE
testimony on the gas turbine, coal and geothermal projects in Utah
The purpose
of Chad Teply testimony was to support the prudence of capital investments in
the new Lake Side 2 combined cycle combustion turbine (“CCCT”) natural gas
fueled resource, certain pollution control equipment retrofits on existing coal
fueled resources, and other significant generation plant projects being placed
in service during the test period in this docket, July 1, 2014 through July
2015. This included the Hayden SCR and the Blundell geothermal resource well
integration project and 1 the Naughton Unit 3 natural gas conversion project.
The Blundell geothermal resource well integration project integrates two 108 new
geothermal resource wells into the Blundell generation system. One production
well and one injection well, along with associated appurtenances, have been
drilled and will be placed in service to support continued reliable electricity
production at the site. Lake Side 2 is nominally rated at 548 MW base load 130
and 97 MW of duct firing for a total net capacity of 645 MW at the average 131
ambient temperate of 52 degrees Fahrenheit. Each combustion turbine exhausts 132
into its own heat recovery steam generator which then commonly supply a single
133 steam turbine generator. The electrical energy generated by Lake Side 2 will
be delivered to a new 345 kV point of interconnection substation (Steel Mill)
where it will tie into the PacifiCorp transmission system.
MidAmerican Energy Company Energy Isolation Program
Mid American
Energy Isolation program sets procedures for maintaining wind components
including lubrication pumps. Tom Daft of Mid American presented the program
focused on keeping wind turbines safe and reliable. There are procedures for the
following • Main Tower AC Tower Breaker • 575 VAC to LVMD; Control Voltage • 50
kVa Transformer • Converter • Pitch Slip Ring • Gearbox Lubrication Pump • Gear
Box Cooler Fan • Yaw Drive System • Hydraulic Brake Unit and 10 other systems.
This Great River Energy unit is a 450-MW, dual-fuel,
three-unit, simple cycle located in Dexter, MN. The plant manager is Tye Stuart.
A demineralizer challenge was solved by Craig Burkett and reported in 2014 in
CCJ Pleasant Valley Station uses demin water for compressor washing, water
injection, fuel-oil purging, etc. This ultrapure water is maintained below 0.5
µS conductivity and at a pH between 6 and 9. In the past, operators would draw a
sample at the pump skid and then use handheld testing equipment in the plant lab
to test the water. Through trial and error and some research, it was discovered
that ultrapure water, in fact, has an affinity for carbon dioxide which can
rapidly affect the results of the tests. To confirm, operators pulled the sample
and immediately placed the handheld conductivity probe into the water and could
see the value increasing in a matter of seconds.
Dissolved carbon dioxide also associates with water
molecules to form carbonic acid; thus having the sample open to atmosphere was
affecting pH readings, too. Personnel decided to change testing methods to
increase the accuracy of results.
Solution - The station procured and installed a system to
monitor pH and conductivity “in process” so that the water does not come into
contact with air, and therefore, it is not getting contaminated by carbon
dioxide. The pH probe and conductivity probe are specifically designed for
ultra-pure water and both output to a common controller for easy monitoring and
calibration. This enables operators to more accurately track demineralized water
quality.
Thermal Chemistry Ltd’s David Addison, a globally
recognized water consultant with years of experience in power plant operations,
told CCJ in a 2013 interview that accurate measurement of total iron in a
combined cycle’s steam/water circuit is critical to understanding the degree of
effectiveness of the cycle chemistry program formulated to protect against
corrosion and deposition.
He reminds that 99.9 percent of the materials contacting
steam and/or water are ferrous-based, including the carbon steel used in HRSG
feedwater, economizer, and evaporator circuits; the P/T11, P/T22, P/T91, and
other alloys specified for superheaters, reheaters, and main steam piping; and
the stainless steels used in condensers, sample lines, etc.
Addison told the editors that one of his goals is to
convince those not currently monitoring iron levels to do so and those using the
incorrect monitoring techniques to change their approach.
Total iron (soluble + particulate iron) should not exceed 2
ppb in condensate and feedwater systems and 5 ppb in the HRSG evaporator
circuits, according to limits recommended by the International Association for
the Properties of Water and Steam. These quantities may seem relatively
insignificant, but given the high flow rates in an F-class HRSG, they translate
to a large amount of iron transport over time. The total iron limits recommended
by IAPWS are referred to in the industry as the “Rule of 2 and 5”—once again,
less than 2 ppb total iron in condensate/feedwater and less than 5 ppb in each
steam drum.
Stressing the need for an accurate and repeatable
measurement of iron transport, Addison identified several grab-sampling and
analysis methods in use that have best-reported detection limits above the
IAPWS’s recommended 2 ppb. They are UV-Vis (Ferrozine method with a 1-cm optical
cell), ICP-AES, and Graphite Furnace AA. Please excuse the jargon, but there’s
no meaningful way to simplify the terminology.
Addison endorsed the Corrosion Products Sampler as one of
the best methods today for measuring total iron, mentioning a unit offered by
Sentry Equipment Corp but acknowledging that there are other such systems on the
market. He added that in-house constructed systems often are seen in the field.
The Sentry unit passes a measured flow of sample through a
0.45-micron particulate filter (a 0.1-micron filter may be preferable). Filters
are removed at the end of the collection period and the captured species
analyzed. This involves acid digestion of the filter and analysis for Fe2+.
Total iron on the filter divided by total sample flow gives the average
concentration of iron in the system at the sampling point during the collection
period.
This 910-MW, gas-fired, 3 × 1 combined cycle plant is
located in Hardeeville, SC.
The plant manager is Steve Palmer who along with Tim
Glover, operations superintendent; Kevin Croft, E&I supervisor and Rusty Mezel,
maintenance superintendent was interviewed for a CCJ article.
A loss of instrument air pressure is a major reliability
concern because instrument-air-dryer purge valves were prone to malfunction,
causing a rapid decrease in instrument air header pressure and subsequent
equipment upset. There is also the risk that the backup air compressor can fail
to start upon the loss of the running unit, putting the facility at risk. The
air compressors and dryer systems are located at the far end of the plant making
rapid response and correction challenging. A reliable, cost-effective backup
system was desired.
After an engineering review, plant staff decided to modify
and configure the existing, GE-supplied, air processing units (APUs) for use as
backup to the instrument air system when 7FA gas turbines are online and
operating in Mode 6 APUs take compressor discharge air, regulate, and cool it
for pulse cleaning of the turbine inlet filters. The instrument-air-system
header previously had been tied into the 7FA inlet filter cleaning system
(supplanting the APUs) to supply clean, cleaning because the plant had excess
compressed-air capacity and was experiencing ongoing maintenance problems with
the APU regulators.
The existing APU control logic was reconfigured into the
Ovation DCS to “open” the corresponding APU blocking valve and allow its
compressor discharge to provide backup to the instrument-air-system header when
header pressure decreases to 90 psig and the respective gas turbine is operating
in Mode 6.Excess moisture is removed by an existing inline drain trap on the 7FA
side of each APU air cooler and a modified inline filter with draining
capability on the header side of each APU cooler. Hot compressor discharge air
also is cooled by the existing cooler on each APU prior to admission into the
instrument air header. Existing APU moisture-separation towers are bypassed, as
the moisture drains are sufficient for short-term, emergency service.
Results - The facility’s instrument air system is backed up
by each gas turbine’s compressor discharge in the event of a low air-header
pressure condition when the gas turbine is operating in Mode 6, eliminating the
risk of a plant trip and/or equipment upset. This design change also allows a
safe, measured response to air compressor and dryer malfunctions when personnel
are not in the immediate area. Modifications were implemented by plant personnel
with some minor material costs. Since implementation, one plant trip was averted
when a dryer purge valve stuck open and the idle air compressor failed to start.
As part of its contractual service agreements (CSAs),
Clarke Energy, an authorized distributor and service provider for GE’s Jenbacher
gas and diesel engines, will connect more than 700 assets globally to GE’s
myPlant Asset Performance Management (APM) solution.
GE’s myPlant APM solution for power generation and gas
compression plants is designed to transform data into actionable intelligence by
joining analytics with domain experts. It also will create a single source of
data for all power generation and gas compression assets across the active
installed fleet, utilizing predictive analytics to identify issues before they
occur, reducing downtime and extending asset life while still balancing
maintenance costs with operation risk.
“Clarke Energy has good reason to advance its use of GE’s
myPlant Asset Performance Management solution. With APM, designated Clarke
Energy engineers are automatically notified about unscheduled generator stops at
customer sites—such as engine trips—via text message or email,” said Anthony
Hayes, group IT director at Clarke Energy. “Clarke Energy’s service engineers
monitor engine performance from different locations to diagnose problems and
support the operator on-site to resolve the issue, reducing site manpower
requirements and increasing engine availability.”
GE’s monitoring solutions enabled with factory
engineer-developed analytics are essential to using data-enabled decisions to
optimize service delivery. Using data to better predict and prepare for upcoming
maintenance will allow Clarke Energy to better manage inventory, enhance
resource planning and execute maintenance. In the end, the customers with a
Clarke Energy CSA will benefit from well-prepared maintenance events, which
reduces downtime.
With the myPlant APM solution, Clarke Energy can better
support the customer when unexpected issues emerge. Clarke Energy technicians
can use myPlant’s predictive analytics to anticipate issues that could result in
unplanned outages. The generator health analytic, for instance, will alert
Clarke Energy when an issue is detected that could lead to bearing failure. By
detecting and acting on such an issue early, an unplanned outage can be moved to
a planned outage, reducing extensive downtime and repair costs. For example, the
downtime from a generator bearing failure on a 3.3-megawatt (MW) Jenbacher J620
gas engine could range from six to eight weeks and cost $160,000 in lost revenue
(depending on feed-in tariffs and downtime). In addition, Clarke Energy’s
factory-certified technicians can remotely diagnose, troubleshoot and solve many
issues on the Jenbacher gas engine. With remote troubleshooting, the customer
avoids unnecessary costs and downtime that may result from sending a field
technician to resolve a minor issue.
“The goal of GE’s Distributed Power myPlant APM solution
for power generation and gas compression plants is to solve large and complex
problems with ease, make real-time adjustments to the assets to increase value
and put more power into the hands of the plant personnel who make critical
operations, business and maintenance decisions,” said Margherita Adragna, senior
general manager—services for GE’s Distributed Power. “By closely linking
predictive analytics to field service activities, GE and Clarke Energy will
enhance our customers’ operations—balancing availability, performance and cost.”
The myPlant APM solution is an application of GE’s Digital
Twin technology. It enables a local monitoring and diagnostics infrastructure to
remotely calculate plant performance every day of operation. By using GE’s
myPlant APM solution, the plant, asset and/or maintenance manager can gain
real-time intelligence needed for making better decisions to achieve the desired
outcomes and increase the uptime of the asset. This approach distinguishes
between real-time and batch algorithmic analytics.
In addition, GE and Clarke Energy are working together on
analytics development and co-creation to jointly co-innovate and accelerate the
development of predictive analytics for all engine types across multiple
industry segments.
Hisham Al Bahkali, GE’s President & CEO for Saudi Arabia &
Bahrain, said “GEMTEC a becomes our first ‘Brilliant Factory’ in the region by
introducing advanced digital industrial capabilities, which will drive the
highest standards of operational efficiency & productivity as well as lower
costs and use real-time monitoring to achieve reduced downtime. In addition,
GEMTEC, which rolled out its first ‘Made in Saudi’ turbines in 2016 It has now
inaugurated a new Heavy Duty Gas Turbine Manufacturing Facility and is creating
an exports hub for technologically advanced gas turbines. Further, Saudi
researchers at GEMTEC work closely with their counterparts at the GE Saudi
Technology & Innovation Center in Dhahran Techno-Valley on Hot & Harsh research
to identify solutions for challenging environments that are not just Saudi
solutions for Saudi, but Saudi solutions for the region and the world.
Academic institutions such as the King Fahd University of
Petroleum and Minerals (KFUPM) and King Abdullah University of Science and
Technology (KAUST) are collaborating with GE on this research, sharpening the
research and innovation skills of Saudi technical talent.
The findings of these collaborative research projects will
be applied to gas turbines manufactured at GEMTEC and to ‘Made in Saudi’ oil &
gas equipment also manufactured in the Kingdom.
The GE Saudi Technology & Innovation Center will be at the
heart of GE’s digital footprint and capabilities in Kingdom, growing
digital-savvy talent in state-of-the-art laboratories with training and
skill-set development programs focusing on start-ups and entrepreneurs in the
digital industrial space. GE is helping develop digital power plants that enable
partners to monitor the operations of every single piece of equipment to avoid
and manage unplanned outages. And what really drives GE’s digital industrial
strategy forward is the active participation of Saudi talent.
Bahkali says that GE has highly qualified software
professionals and technical talent ‘waiting in the wings’ to become partners in
the Kingdom’s growth. GE is providing them the platform to contribute their
skills for the nation.
McIlvaine Company
Northfield, IL 60093-2743
Tel:
847-784-0012; Fax:
847-784-0061
E-mail:
editor@mcilvainecompany.com
Web site:
www.mcilvainecompany.com