Operating Experience With a 42.5 MW Gas Turbine Used in a Cogeneration Plant at a Paper Mill in the U.S.

1989 ◽  
Author(s):  
S. T. O’Neill
Keyword(s):  
Gas Turbine ◽  
Operating Experience ◽  
Paper Mill ◽  
Cogeneration Plant ◽  
History Of ◽  
Operating History ◽  
Base Load ◽  
The U.S ◽  
Reliability And Availability

The CW251B10 Gas Turbine has been in service at the Procter & Gamble Paper Mill located at Mehoopany, Pennsylvania since July 1985, and has exhibited outstanding reliability and availability since that time. It operates continuously at base load supplying both electricity and process air for the plant. This paper reviews the operating history of the gas turbine, and describes some of the problems experienced, together with their solutions.

User Experience: Operating a 300 MW Base Load Cogeneration Plant With High Water Injection Rates to Control NOx Emissions

1989 ◽  
Author(s):  
William E. Hauhe ◽  
Gary L. Haub ◽  
Charles O. Myers ◽  
Donald C. Guthan ◽  
David O. Fitts
Keyword(s):  
Gas Turbine ◽  
User Experience ◽  
Water Injection ◽  
High Water ◽  
Operational Reliability ◽  
Oil Field ◽  
Nox Emissions ◽  
Cogeneration Plant ◽  
Base Load ◽  
Reliability And Availability

This paper describes user experience with the operation and maintenance of a gas turbine based cogeneration plant operating at base load while injecting up to 80 gpm (303 l/min) of water to control NOx emissions to 42 ppmv (at 15% O2). The plant, located in the Kern River Oil Field, near Bakersfield, California, has produced an average of 294.6 MWe and 1.903 million lbs/hr (0.863 million kg/hr) of steam since achieving commercial operation in August, 1985. To date, the plant has achieved an operational reliability and availability of 98.9% and 95.4%, respectively. The effects of water injection on combustion hardware, as well as, overall gas turbine reliability and availability and equipment enhancements will be discussed.

The PGT2, a New 2-MW Class Efficient Gas Turbine: Applications and Operating Experience in Cogeneration

1996 ◽  
Author(s):  
Erio Benvenuti ◽  
Marco Sargenti
Keyword(s):  
Gas Turbine ◽  
Pressure Ratio ◽  
Operating Experience ◽  
Paper Mill ◽  
Medium Size ◽  
Economic Evaluations ◽  
Cogeneration Plant ◽  
Two Stage ◽  
Paper Mills ◽  
Operational Data

The PGT2 is a single-shaft gas turbine with a 2 MW ISO electric output that, after an extensive factory development program has been launched into industrial service with a number of cogeneration applications in small-medium size industries. The two-stage high pressure ratio compressor combined with the single-can combustor and the two-stage air-cooled transonic turbine provides a compact and rugged architecture. The turbine inlet temperature in the 1050–1100 °C class and the 12.5:1 pressure ratio provide a 25% electrical efficiency and a high exhaust temperature that make this machine attractive for a variety of both civil and industrial applications like hospitals and pulp and paper mills, textile, tiles, cement, glass and food production. The exhaust heat recovery boiler can be either a commercial unit or compact once-through type of proprietary design that is housed in a vertical exhaust duct to substantially reduce powerplant footprint area when space is limited. The first application that has provided the most extensive operating experience so far is cogeneration in a paper mill in central Italy. Detailed studies on the potential energy saving and on the return of investment cycle were made in collaboration with the client, and provided a valuable basis for further studies that led to additional orders for paper mills, textile and tile industries. The first installed unit is a package comprising a once-through-flow boiler that was full-load tested at the factory before shipping. Commissioning of the cogeneration plant was started in 30 days after shipment and the plant was taken over by the client in less than three months. A dedicated telephone line allows the power plant to be monitored directly from Florence, thus making it possible to gather operational data in real time and to provide this first customer with prompt assistance during the 4-year service and maintenance contract period. This paper describes the PGT2 design and performance features, the technical and economic evaluations made for the first application, the cogeneration plant layout and a summary of the most significant operational data collected in the initial months or regular service in the paper mill.

Strategy for a Cost Optimized Operation of a Flexible Cogeneration Gas Turbine Plant

2000 ◽  
Author(s):  
D. Hein ◽  
K. Kwanka ◽  
M. Nixdorf
Keyword(s):  
Gas Turbine ◽  
Control Strategy ◽  
Operating Experience ◽  
Economic Potential ◽  
Cogeneration Plant ◽  
Turbine Plant ◽  
Mode Of Operation ◽  
Gas Turbine Plant ◽  
Technical Framework

A new gas turbine cogeneration plant based on the Cheng cycle was installed to supply electricity and heat for the Technische Universität München’s campus site at Garching. To utilize fully the Cheng cycle flexibility, an optimizing system was developed which controls the mode of operation continuously and adapts the point of operation without manual interface. Only with such a system it is possible to exploit the full economic potential of the system. The paper presents the technical framework and some aspects of the control strategy used to minimize the costs based on three years of operating experience.

501F/M701F Gas Turbine Uprating

2001 ◽  
Author(s):  
E. Akita ◽  
H. Arimura ◽  
Y. Tomita ◽  
M. Kuwabara ◽  
K. Tsukagoshi
Keyword(s):  
Power Generation ◽  
Gas Turbine ◽  
Operating Experience ◽  
Combined Cycle ◽  
Design Improvement ◽  
Reliability Improvement ◽  
The World ◽  
Commercial Operation ◽  
Cycle Efficiency ◽  
Reliability And Availability

The share of the gas turbine combined cycle plants tends to increase rapidly in the world of power generation. Under the circumstances, MHI is developing the several kinds of gas turbine to meet each customer’s needs. The ‘F’ series’ engine, which has a firing temperature of 1350–1400 degree C, is predominant in the current market, and the reliability improvement is constantly performed. As a result, the operational hours of 50,000, and the combined cycle efficiency of 55–57% (LHV) is achieved for F-series combined cycle. During the operating experience, any events occurred in field operation is solved. Also, countermeasure was implemented on every machine. Furthermore, robust design improvement is introduced, and commercial operation of the design achieved higher reliability and availability. In this paper, the operating experiences, design improvements and the F series gas turbine uprating program are introduced.

Continued Enhancement of SGT-600 Gas Turbine Design and Maintenance

2008 ◽  
Author(s):  
Vladimir Navrotsky ◽  
Mats Blomstedt ◽  
Niklas Lundin ◽  
Claes Uebel
Keyword(s):  
Life Cycle ◽  
Gas Turbine ◽  
Gas Turbines ◽  
Life Cycle Cost ◽  
High Reliability ◽  
Medium Size ◽  
Power Turbine ◽  
History Of ◽  
And Control ◽  
Reliability And Availability

Current power generation and oil & gas markets are dynamic with continuously growing requirements on gas turbines for high reliability and availability and low emissions and life cycle cost. In order to meet these growing requirements on the gas turbines, the OEM should sustain continued product improvement and employment of innovative solutions and technologies in the area of design, operation and maintenance. This paper describes the successful development and operation experiences of SGT-600 Siemens’ medium size gas turbine and in particular the latest achievements in maintenance and life cycle improvements. High reliability and availability of SGT-600 gas turbine were enabled by further improvements and modifications of the combustor, compressor turbine blade 1 and vane 1, power turbine diffuser and control system. The developed modifications enable operators to utilize the opportunity: • to extend the life cycle of the engine beyond 120,000 EOH (Equivalent Operating Hours), up to 180,000 EOH, depending on the previous operation profile and history of the installation; • to extend the maintenance intervals from 20,000 EOH to 30,000 EOH and that to increase the availability of the engine by up to 1%; • to reduce the emission level to the latest SGT-600 standards.

scholarly journals Ten Years’ Operating History of a Large Gas Turbine/Recompression Train

1989 ◽  
Author(s):  
C. Peter Conquergood ◽  
Dave Blauser ◽  
Peter Willbourn
Keyword(s):  
Gas Turbine ◽  
Heat Recovery ◽  
Waste Heat Recovery ◽  
Waste Heat ◽  
Compressor Unit ◽  
History Of ◽  
Three Stages ◽  
Operating History ◽  
Canada Limited ◽  
Turbine Exhaust

In 1978, Shell Canada Limited commissioned a large aero-derivative gas turbine driven compressor unit in its Waterton Straddle Plant. This unspared unit provides the primary recompression service in the “Deep Cut” ethane extraction facility. Significant operating features of this unit include flat rating and three stages of waste heat recovery from the turbine exhaust. Throughout its history, this unit has demonstrated over 99% reliability and has operated for long periods without significant maintenance. All routine turbine maintenance has been accomplished on-site. This paper describes the features of the installation, the operating and maintenance philosophy, and the experience obtained from ten years’ service, thus providing the reader with insight in regard to features and practices which can provide for a successful installation.

U.S. Navy Rolls-Royce Allison 501-K34 Operating Experience

2000 ◽  
Author(s):  
Dennis M. Russom ◽  
Robert L. Jernoske
Keyword(s):  
Life Cycle ◽  
Gas Turbine ◽  
Operating Experience ◽  
Life Cycle Costs ◽  
Prime Mover ◽  
Turbine Generator ◽  
Prototype Experience ◽  
Generator Sets ◽  
The U.S ◽  
Future Plans

The Rolls-Royce Allison (RRA) 501-K34 serves as the prime mover for the Ship Service Gas Turbine Generator sets (SSGTGs) of the U.S. Navy’s DDG-51 Class ships. Navy experience with the 501-K34 began in 1988 with the testing of the first prototype. Experience to date includes over 700,000 fired hours on a growing fleet of engines. This paper explores that operating experience and discusses future plans to improve the engine’s operational availability while lowering life cycle costs.

Design Considerations in the Development of a 38 MW Gas Turbine Cogeneration Facility

1990 ◽  
Author(s):  
Andrew D. Hall ◽  
William E. Hauhe
Keyword(s):  
Gas Turbines ◽  
Catalytic Reduction ◽  
Water Injection ◽  
Operating Experience ◽  
Set Design ◽  
Design Features ◽  
Energy Company ◽  
Design Considerations ◽  
History Of ◽  
Operating History

Cogeneration has proven to be an ideal application for gas turbines, one which subsidiaries of Texaco Producing Inc. and Mission Energy Company have developed in three successful projects to date. The 38 MW Mid-Set project is the latest, having been commissioned for commercial operation in April, 1989. Several of the Mid-Set design features were developed from past operating experience, while other design features were employed to meet requirements specific to the project. Strict pollution control required the use of water injection, selective catalytic reduction, continuous emissions monitoring and minimal production of waste water. Other design considerations were plant availability, operability and efficiency for the continuous, base load operation of a turbine-generator. The design features and initial operating history of the Mid-Set cogeneration plant are described in this paper.

A Higher Turndown Flexibility on AE64.3A Gas Turbine: Design and Operating Experience

2011 ◽  
Author(s):  
Federico Bonzani ◽  
Luca Bozzi ◽  
Alessia Bulli ◽  
Andrea Silingardi ◽  
Domenico Zito
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Energy Demand ◽  
Power Plants ◽  
Operating Experience ◽  
Maintenance Cost ◽  
Power Demand ◽  
Service Market ◽  
Low Load ◽  
Base Load

Italian power generation market is living today a period of substantial changes due to the liberalization process, climate issues, natural gas price fluctuation and the uncertain future of nuclear and coal. In this framework, many gas turbine power plants, originally designed to operate mainly at base load, feel the necessity to be flexibly and profitably operated into the dispatch and ancillary energy service market. In particular, many operators ask for the possibility to operate their gas turbines intermittently, frequently cycling and quickly ramping up and down to satisfy energy demand. Such using drafts new trade off between profitability and maintenance cost. From this point of view it’s not unusual to shut down the engine when the power demand is low if the unit cannot be cost effectively parked at a suitable low load and then quickly ramped up to base load when the power demand is higher. The main barrier against lowering the minimum load of the gas turbines is the increase of the CO emission. When the engine operates close to its turndown load the compressor airflow is such that the heat released by the flame cannot properly support the conversion of CO into CO2. In such a condition, the power plant will not comply with the environmental legislation and must be operated at a higher load or, worse, shut down. An operating strategy has been devised to face up such problem. It is based on the adjustment of compressor IGV (Inlet Guide Vanes) and the optimisation of cooling air consumption in order to keep the proper amount of combustion air close to the turndown load. This paper shows the feasibility check, the installation and final field tests of the low load turndown upgrade on a AE64.3A gas turbine which allowed to operate the unit in a more cost effective way even when the power demand is low.

Development, Testing, and Implementation of a Gas Turbine Starting Clutch With Manual Turning Feature for U.S. Navy Ships

2006 ◽  
Vol 129 (3) ◽  
pp. 785-791 ◽  
Author(s):  
Morgan L. Hendry ◽  
Matthew G. Hoffman
Keyword(s):  
Gas Turbine ◽  
Operating Experience ◽  
Turbine Rotor ◽  
Turbine Generator ◽  
Rotor Rotation ◽  
Turbine Generators ◽  
Generator Sets ◽  
The U.S

Most gas turbine generators rely on an automatic-engaging, free-wheel clutch to connect a starting motor to accelerate the gas turbine generator from zero to some intermediate speed to enable ignition and then provide torque assistance to a higher speed until the gas turbine is self-sustaining. The U.S. Navy has used various designs of starter motors and clutches for its gas turbine fleet. In addition, there has been a requirement to periodically borescope each gas turbine, which has necessitated removal of the starting system and clutch assembly in each instance. This paper examines the U.S. Navy experience with starting clutches and provides details of the development and testing of a synchronous-self-shifting clutch with an additional, stationary, manual turning feature to provide very slow and precise gas turbine rotor rotation for borescope purposes. This paper also gives details of the installation of the first two prototype clutches on the USS Ramage, DDG 61, operating experience for approximately four years, and possible future installations of this type of clutch in U.S. Navy gas turbine generator sets.

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