Gas Turbine: Introduction and Brief Technical Evaluation Guidelines

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Agenda
A. Introduction to Gas Turbine B. Technical Bid Evaluation Guidelines

A. Introduction to Gas Turbine

1. Gas Turbine Components and Parts 2. Gas Turbine Applications

Component and Parts

Gas Turbine Component (Ground-based engine)

Gas Turbine Component (Turbojet engine)

LP compressor case IP compressor Intermediate case IP turbine

LP turbine

LP compressor rotor

High speed gear box

HP systems

Gas Turbine Component

Compressor: draws air into the engine pressure it and deliver to combustion chamber Combustion Chamber: receives air from compressor mixing with fuel sprayed from nozzle burn the mixture to generate maximum possible heat energy (initiate by igniter plugs, isolated after start-up and remains continuous until the fuel supply is shut off) designed to provide mixing, burning, dilution and cooling; by the time the combustion mixture leaves the combustion system and enters the turbine, it is at a mixed average temperature Turbine: Turbines are generally easier to design and operate than compressors, since the hot air flow is expanding rather than being compressed.

Gas Turbine Component (cont.)

Inside the Package:
Fuel System Bearing Lube Oil: Tank, Filters, Pump Fire and Gas Detection System Starter / helper driver: Pneumatic, Hydraulic, Variable Speed Seal gas / oil

Outside the Package:

Enclosure and Fire Protection System Inlet System: Air filter, Silencer Exhaust System: Silencer, Stack, Lube Oil Cooler, Motor Control Center, Switchgear Fire and Gas Detection System Starter / helper driver: Pneumatic, Hydraulic, Variable Speed Seal gas / oil

Human Machine Interface:

Machinery monitoring and protection Driven Load Regulation Communications (SCADA) interface

Gas Turbine Component (cont.)

Sensing and Control Instrumentation: Temperature sensors Pressure sensors Flow sensor / surge control Position sensor Velocity probes

Theory of Operation

Brayton Cycle: (1 - 2) Air is compressed isentropically (2 3) Combustion at constant pressure (3 4) Expansion at turbine isentropically

Application: As Generator

Application: As Mechanical Drive

B. Evaluation Guidelines
Decide the best sizing use guidance / handbook or based on similarity in past project Decide shaft arrangement single or twin shaft Decide the best type Aeroderivative or Heavy Duty Evaluate Efficiency, performance and loss update process calculation

Evaluation Guidelines (cont.)

Evaluate Hazardous Class review inside and outside enclosure Materials gas composition and site condition Monitoring System discuss with operation team (or operation requirement) API review study exception and deviation maintaining performances compliance

Evaluation Guidelines (cont.)

Decide the best sizing from various manufacturer see Gas Turbine World Handbook magazine
Consideration: - price per kW - Efficiency LHV Review Manufacturer population in typical industries: Solar Turbine Booster Application GE LNG and Petrochemical
Saturn 20: Centaur 40: Centaur 50: Taurus 60: Taurus 70: Mars 90: Mars 100: Titan 130: 1.2 MW 3.5 MW 4.6 MW 5.8 MW 7.7 MW 9.9 MW 11.2 MW 15.3 MW GE Frame 3: GE Frame 5: GE Frame 6: 15140 HP 26400 HP 50700 HP

Evaluation Guidelines (cont.)

Decide the best shaft Single or Twin Shaft
Single Shaft: used for power generation Twin Shaft: for mech. drive: allows variable speed operation for power generation: transient response inferior to single shaft unit Twin Shaft Power Turbine PTC test: Smaller cranking requirement Air compressor runs at most efficient speed

Evaluation Guidelines (cont.)

Decide the best type Aeroderivative vs Heavy Duty

Evaluation Guidelines (cont.)

Heavy Duty vs Aeroderivative
Heavy Duty / Industrial Type: - Heavy Casing - Massive stiff shafting with journal bearing - Requires pre-post lube - Cheap but excessive lube - Less frequent maintenance

Evaluation Guidelines (cont.)

Heavy Duty vs Aeroderivative Aero derivative: Light Casing Rotor shafting: 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

Evaluation Guidelines (cont.)

Evaluate Efficiency: Efficiency 30% means: 70% of rotational energy produced is required to drive air compressor in order to maintain sufficient air flow for combustion

Evaluation Guidelines (cont.)

Evaluate Performance and Loss - Site Rated correction: for Indonesia: 82% of ISO Rated, mostly due hotter Temp T up, rho up, mass flow down: power down for Indonesia: 60% RH - Fuel Type - In the case of Dual fuel: Liquid hotter and less efficiency than gas Engine efficiency liquid 1.3% lower

Evaluation Guidelines (cont.)

Evaluate Performance and Loss - Heat Rate: Amount of heat energy to produce output - Inlet Loss: P drops through inlet filters - Exhaust Loss: P drops through stack, silencer, WHR (be aware that this will create backpressure)

Evaluation Guidelines (cont.)

Evaluate Lube System - Sleeve & Thrust Bearing typical heavy duty mineral based oil common lube - Anti friction type ball and/or roller bearing typical aero derivative synthetic oil need scavenging system

Evaluation Guidelines (cont.)

Hazardous Class Certificate: - If possible use OEM standard: IEC (Eropa) or NEC (USA) - Use equivalence of IEC-NEC Material for ducting, silencer and venting: - Gas composition - SS or CS or CS with internal SS

Evaluation Guidelines (cont.)

Monitoring System: - System 1 (GE) or Turbotronic (Solar) Be aware of Duplication (by function) and Interface problem

Evaluation Guidelines (cont.)

API review: - Convenient purchasing document force OEM to supply similar equipment - Limit misunderstanding - Exception are allowed - API 616 (1998) is not for aero derivative, except stated by client - Alternative design: deviations and reasons

Evaluation Guidelines (cont.)

API review: - Site rated power dont forget to ask OEM guarantee point - API mechanical test run - PTC closed loop test PTC 10 Comp + PTC 22 GT (usually type 2) - Review API 617 as well speed variation control for GTCP

Evaluation Guidelines (cont.)

Scope for Split Arrangement (by EPC or Mfr): Anti Surge Valve Lifting Kit Fuel Valve SS or Aluminum Water Wash Cart Water Mist or CO2 Suppression Platform Exhaust Stack FAT / SAT

Evaluation Guidelines (cont.)

Technical Bid Evaluation: - List up company (or owner) spec and API requirement - List up deviations for approval discuss with Mfr!! - List up deviations to API be realistic!! - Complete Item Check List - Performance Comparison - Guarantee Comparison

Evaluation Guidelines
(Typical) Utility Review: - Electrical System 3 ph, 1 ph - Compressor Dry Seal System P, flow rate, External - Start System Direct Drive - Natural Gas Fuel System P, flow rate, T - Lube Oil Cooler

References
Manufacturer's Publications Gas Turbine World Handbook Publications Internet (public domain) information Author's experience working as EPC company / Owner company / Consulting company 's engineer

hamdi@hammer-engineers.com