Turbo Phase overview

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Turbophase utilizes a 2MW reciprocating gas (or diesel) engine to drive an intercooled compressor and uses the waste heat from the engine to heat the air up

Turbophase process is simple and efficient

• Turbophase =Intercooled

Compressor • Gas turbines = Axial Compressor

The Intercooled process is 34% more efficient than the axial process at generating hot compressed air

Exhaust in

Exhaust out

Cold compressed air in

Hot air out

TurboPHASE Overview

2

TurboPHASE Overview

• Increased GT Output • Increased Exhaust Mass Flow at lower exhaust temperatures • Increased Steam Production, Steam Turbine Output

Generator Generator GT Compressor

GT Turbine

Combustor

Steam Turbine HRSG

Injection Air Added by

TurboPHASE

Reciprocating Engine

High Efficiency Compressor Recuperator

Reciprocating Engine

High Efficiency Compressor

Increased MW

Increased MW

Increase Mass Flow

Exhaust Air Added by

TurboPHASE

TurboPHASE System adds the missing air back into the combustion

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TurboPHASE Overview

Recuperator Radiator Overflow

Muffler

Air Line to GT

Intercoolers Compressor Gearbox Engine

Heat Exchanger

Engine Exhaust Air From Compressor

Cooling Water In/Out

Silencer

Air Inlet Filter, Meets GT OEM Specs

Turbophase is made of name brand production equipment

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TurboPHASE Overview

Modules are factory tested prior to shipping

Certificate of Compliance: • Air flow generated • Air temperature • Air pressure • Fuel consumption • Sound level • Vibrations • Auxiliary load • Safety functions

Turbophase modules hit the ground running with no surprises

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TurboPHASE Overview

Multiple modules can be hooked up to one or more gas turbines

Modularity provides • One size fits all, just vary the

number of modules • Low production cost • Rental/Leasing available • Smooth power ramping: 0->Full

Modularity provides flexibility and low cost

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TurboPHASE Overview

Designed for simple integration Interconnects

• Fuel: NG @ 5psi • Water: zero consumption, 600gpm flow in and out • Electricity: 480V, 35kW per module • Foundation: floating slab or concrete foundation, subject to local civil

codes • Controls: one fiber or Ethernet cable • Injection and Exhaust air: one connection to existing GT locations • Recip engines meet emissions reqt’s of NSPS 40 CFR 60, Subpart JJJJ;

eliminates need for initial performance test at site • GT Concentration remains unchanged out of stack. TPM exhaust routed to

HRSG and existing SCR

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TurboPHASE Overview Designed for safe & proper GT operations Item Mitigation

Air Quality Air is filtered with Nema 4, Merv 13 filters, IGT industry standard

Foreign Object Damage (FOD) 50 Micron strainer located in Injection Air header prevents FOD reaching the gas turbine

Combustion Stability Increasing air flow with TurboPHASE drives the combustion system towards its ISO day design condition, improves combustion dynamics and increasing velocities

Control Settings No control settings are changed in the gas turbine. The current logic manages changes in mass flow. The TPM controls are seamlessly integrated into the plant DCS and AGC. Control signal is 1-way.

Maintenance Impact No maintenance impact to any parts (CI, HGP) due to increased mass flow.

Trip Settings The injection air is isolated from the gas turbine with two control valves that fail closed or close on GT / TPM trip signal. The vent valve normal operation is open to atmosphere.

Start Permissives Ready to Start, Ready to Inject logic set to prevent unwanted operation

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TurboPHASE Overview

Turbophase air cooler option eliminates need to tie into plant cooling water

Only water required is on initial fill of the system

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TurboPHASE Overview

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TurboPHASE Installation in Middle East

Turbophase simply adds the missing air and power back to the gas turbine that is naturally missing due to high ambient temperatures and altitude

Site Conditions: • 45-55C (122F)

ambient temp • 200m altitude GT output 122MW @50C • 27% below ISO rating • Missing 27% air and

output

2 Standard Gas modules tested

Air out Gas In

Principle is simple

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Tie into Gas turbine and borescope took less than one day

Balance of installation was complete 90 days after notice to proceed: • Air line • Gas line • Air pulse Pre-filter

Installation is simple and fast

• Closed loop cooler • 2 Modules • Controls

2 Modules Cooling Tower Air and gas line

Air tie into IBH line

Gas tie in

Pulse air pre-filter


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Every time units are turned on/off, incremental MW and fuel was measured (every day) 1. Net Power of GT existing customer MW meter 2. Auxiliary load validated by customer (35kw per module, 50 kW pumps, 75 kW fans,

185 total for the two modules) 3. GT Fuel existing customer meter 4. TPM Fuel new meter 5. Net Power = 1-2 6. Net Plant heat rate = (3+4)/(1-2)

Turbophase demonstrated power output, efficiency, part load, and life extension

Turbophase is an extremely flexible system and very simple to measure the performance

• Demonstrated Base and part load fuel efficiency with air injection • Demonstrated Base Load output with parts life extension 24,000 hrs to 32,000 hrs

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115

120

125

130

135

140

145

90 95 100 105 110 115 120 125

GT O

utpu

t (M

W)

GT Inlet Temperature (deg F)

No injection 1 TPM injecting 2 TPM injectingLinear (No injection) Linear (1 TPM injecting) Linear (2 TPM injecting)

• Demonstrated 98% availability - ran 2 modules 10 hours per day for the peak, 60 days straight • Tested to 122F ambient • 4.5MW/5.4MW per module –Scaled to 6 modules = 27MW Simple Cycle, 32MW in Combined Cycle • Performance validated every time the modules are turned off and on

Economic Benefits of TurboPhase remain constant all ambient conditions

Power Increase

~9MW Power increase with 2 modules (Simple Cycle)

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• Demonstrated 98% availability - ran 2 modules 10 hours per day for the peak, 60 days straight • Tested to 122F ambient • Demonstrated 0.85% GT heat rate improvement per module – scaled to 6 modules =5.4% • Performance validated every time the units are turned off and on

Economic Benefits of TurboPhase remain constant all ambient conditions

HR Decrease

10,100

10,200

10,300

10,400

10,500

10,600

10,700

10,800

90 95 100 105 110 115 120 125

Heat

Rat

e (B

TU/k

Wh)

GT Inlet Temperature (deg F)

No injection 1 TPM injecting 2 TPM injectingLinear (No injection) Linear (1 TPM injecting) Linear (2 TPM injecting)

1.7% HR decrease with 2 modules

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Turbophase Power and efficiency are easy to measure from the second they are turned on

TPM1&TPM2 Injection

Start ofInjection

FullInjection

NoInjection

StoppingInjection

+9MW

Time

GT M

W M

eter

134 132 130 128 126 124 122 120 118 116

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TurboPHASE Installation in United States

• TPMs connected to common header

• Common header feeds all GTs

• Air can be directed to any combination of GTs

• Integrated into existing cooling loop

• Small footprint

Modular TurboPHASE System fits within existing plant

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• New Tee welded into existing line

• Connected to existing IBH line

• External to enclosure • Injection control valve

bolted to Tee flange • TPMs located 500+ ft

away from injection flange

Integrated to existing turbines without outage

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TurboPHASE System controls integrated to DCS • No changes to GT Controller, Gas turbine controls are completely unaffected • DCS provides Output demand to TPM • TPM converts output demand to pressure and flow, internal PLC • Permissives and trip functions aligned with GT operations

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Incremental power is proportional and instantaneous to air injection rate • Several Failure (TPM Trip) scenarios were tested • Air Injection can be used for high speed regulation

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Measured results confirm predicted TruboPHASE System performance Predicted Test 1 Test 2 Test 3 Average Total Incremental Power (MW) 6.81 7.27 7.26 7.18 7.24 (+6%) Incremental Heat rate (BTU/kWh) 8738 8820 8748 8792 8787

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Rapid trip test successful • Typical GT Controller updated in ~10 milliseconds • Valve response in ~100 milliseconds • GT responds to TPM Trip (loss of air) as planned in 2 seconds • Combustion Process more stable (rich event) with TPM trip

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GT Compressor Limits protected by GT controller • Significant compressor stall margin exists at base load • Compressor Stall Parameter limits defined in Mark Controller • Compressor stall Margin, generator limit and shaft limit would allow 25% air injection, 50%

power increase on an 80F to 100F day

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Customers should contact: Steve Quisenberry Vice President (USA) +1 561 339 2096 [email protected] www.powerphasellc.com

tel:%2B1 561 339 2096

tel:%2B1 561 339 2096

http://www.powerphasellc.com/

Technology

Turbo Phase overview