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Fuel Gas Booster Compressor Specification & Control, A Case Study
Gas Electric Partnership Conference Houston, TX Feb 2nd & 5th 2016 Christean Kapp, HOERBIGER
Classic Gas Turbine & Power Plant Types
February 2-5, 2016 2
Heavy Industrial
Light industrial
Aero-derivative
Powers (MW) 25-350 5-50 5-118 Shaft Configuration
single PG single shaft
Multi shaft
Baseload Plants + + +
Peaker Plants - + +
Simple Cycle + + + Combined Cycle + +
Typical Profile: Low Nox/CO Emissions Gas Turbines require very low oil contamination and low pulsations to avoid auto combustion and mechanical issues in combustion systems. Aero-derivatives require the highest fuel gas pressures and through their multi-shaft designs and frequent peaker plant use vary not only flow but also fuel supply pressure considerably.
Fuel Gas Compressor Specifications & Control
Types of Fuel Gas Boosters
February 2-5, 2016 3
Oil Screw
Oil Free Screw
Non Lube Recip
In Line Turbo
Integrally Geared Turbo
Efficiency - - + - + Oil in Gas - + + + + Emissions - +
( if BCD selected )
- (multi shaft buffering)
MAINTEX - + Operating Range
++ ++ ++ - +
CAPEX + - + -
Typical Profile: Discharge Pressure up to 300 PSIG for Frame Turbines, up to 600 PSIG+ for modern aero-derivative gas turbines. Suction pressure fluctuates all the time. Base Load Plants are less onerous than peaker plants where flow fluctuates all the time with changing power demand. Fuel Gas Compressors can be rated at several hundred or several thousand HP.
Fuel Gas Compressor Specifications & Control
Common Control Options for Compressors
February 2-5, 2016 4
Oil Screw
Oil Free Screw
Non Lube Recip
In Line Turbo
Integrally Geared Turbo
Inlet Guide Vanes (IGV)
+
Suction Throttle
- - - - -
Recycle -- -- -- -- --
Suction Throttle Raises pressure ratio and is inefficient. Limited range on low suction pressures.
Recycle: Gas already compressed is expanded to suction for recompression. Slow and inefficient. Large range
IGVs: Used on Integrally Geared Turbos , effective but turndown limited to app.50%
Screw compressor efficiency chart
Fuel Gas Compressor Specifications & Control
Common Control Options for Compressors
February 2-5, 2016 5
Oil Screw
Oil Free Screw
Non Lube Recip
In Line Turbo
Integrally Geared Turbo
Slide valve
+ +
Variable Speed
- - - + - (redundant to IGV)
Stepped Unloaders
-
Stepless Unloader
+
Slide valve: Effective, large turndown but slow. Screws only.
Stepped Control: Partially effective. Recips only.
Stepless Control: Large operating range efficient, quick response. Recips only.
Variable Speed : Expensive above 500 HP. Proven. Harmonic Vibrations!
Fuel Gas Compressor Specifications & Control
eHydroCOM Working Principles & Animation
February 2-5, 2016 6 Fuel Gas Compressor Specifications & Control
Reducing Oil & Fugitive Emissions
February 2-5, 2016 7
Gas Turbine OEMs require clean fuels with very little oil contamination. This is in particular true with gas turbines with high compression ratios and/or with dry low emissions systems (DLE/DLN/SOLONOX). NON LUBE Ideal solution is the specification of a slow to medium speed non-lube compressor. (max. 900 rpm ). In addition special care needs to be taken to ensure that rider rings are adequately dimensioned for optimum reliability. Non-Lube Polymers such as HY101 should be considered.
PACKING BCD low emissions packings work well to reduce fugitive emissions in operation and standstill under low fuel gas booster pressures by up to 70%.
Fuel Gas Compressor Specifications & Control
Case Study: Aero-Derivative CCP Slovakia Installed 2010
February 2-5, 2016 8
20-46 bar, 990 rpm, 900 HP Fuel Gas Compressor
48 MW ISO, aero-derivative gas turbine, waste heat recovery and steam turbine generator.
Fuel Gas Compressor Specifications & Control
The Reliability Efficiency Environmental Study
February 2-5, 2016 9
The REE study confirmed customer complaints about low reliability and low efficiency on this new compressor utilizing industry standard equipment with stepped controls, plate valves and radial/tangent packing.
A time study confirmed that the compressor was running below 50% load on average with large swings. Each call-out for four hours to fix the compressor evaluated at app.10,000 $ excl. parts. (incl. loss of production)
Fuel Gas Booster Losses 0.5% of GT power production !
The Fix
February 2-5, 2016 10
• CP Profiled Plate Valve with PowerPeek™ • BCD Packing Rings • Next Generation OFD Oil Wiper rings • eHydroCOM • On-Line Condition Monitoring
eHydroCOM ideal for retrofit as no hydraulic oil system, no local instrumentation and plug and play cabling
Fuel Gas Compressor Specifications & Control
The Final Result
February 2-5, 2016 11
Fuel Gas Booster with installed eHydroCOM. Demonstration of Valve & Stepless Unloader.
Operating since October 2014 w/o a fault.
$/KWH
App. 75,000 $/Year
12 February 2-5, 2016
Thanks for your attention - ANY QUESTIONS ? Presenter: Christean Kapp, Sr VP E-mail: [email protected] HOERBIGER Compression Technology, Houston, TX
12 Fuel Gas Compressor Specifications & Control
