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Tutorial - 1-Fuel System Requir.
Tutorial - 1-Fuel System Requir.
Figure 2: Aero-derivative - LM2500 gas turbine with DLE Figure 4 shows a comparison of injecting water or steam into
combustor (courtesy GE Energy) the primary zone with the newer DLE/DLN solution. {2} Other
Types of combustion emissions regulated; Legislation, OEM factors to note with wet injection are the need for a large
and Customer Requirements quantity of de-mineralized water and the impact on the service
Over the last 25 years, increasing pressure has been placed on regime, with more frequent planned interventions a
the gas turbine OEM’s to develop less polluting products. The consequence of this option. The ratio of water, or steam, to fuel
US Clean Air Act set new standards for emissions compliance, used (WFR or SFR) results in lower NO x, but can impact CO
with the European Union (EU) and other countries soon emissions in a detrimental manner. Where a service retrofit of
following suit with more demanding legislative requirements. existing gas turbines was made to include DLE combustion, the
Consequently low emissions became the norm and not the environmental benefit was significant, offering almost a 5 times
exception. There are a wide variety of pollutants to consider, reduction in NOx emissions compared to previous abatement
but in particular Oxides of Nitrogen (NOx), Carbon Monoxide system employed (Figure 5).
(CO) and unburnt hydrocarbons (UHC). {1} Relative Emissions Performance
1 2 (Pipe line Quality Gas at Full Load)
In addition, the major gas turbine OEM’s, along with a large
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number of Oil & Gas companies, have their own policies with 160 Expecte d Guarante ed
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emission equipment even in locations where no formal 100 NOx
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emissions signature. These are offered in both annular and can- 120.0
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and reduce the production of NOx. This has been successfully Months
0 .0 0 0 1
1: Lean-premixed pre-vaporised combustion
2: Staged Combustion 0.0000 1
3: Catalytic Combustion 0 .0 0 0 0 0 1
1 300 15 00 17 00 190 0 210 0 230 0 2500
PreChamber
Radial Swirler
A lean pre-mix combustor design comprises 4 main features:
Pilot / Secondary
Fuel / air injection device Fuel Supply
Transition duct
This duct controls and directs the hot combustion gases towards
the first stage nozzle and typically includes effusion cooling.
Materials:
All components of the combustion hardware are manufactured
from conventional materials typically used in this part of the
Figure 14: Schematic of the Dry Low Emission combustor gas turbine. Burners are routinely made from stainless steel,
concept with the application of a thermal barrier coating in key areas.
Combustion chambers are manufactured from Nimonic steels
Gaseous and liquid fuels are introduced, in two stages: with thermal barrier coatings applied to the inner liner surface.
Main, which results in a high degree of
‘premixedness’ and hence low NO x emissions The description provided above refers typically to arrangements
Pilot, which is reduced as the load demand increases where control of the fuel is maintained across the full operating
and is used to ensure flame stability regime of speed, load and ambient conditions. For other types
The pilot is arranged such that as the pilot fuel split increases, of configuration, including the annular combustion designs
the fuel is biased towards the axis of the combustor. installed in aero-derivative type GT designs should be
considered at this point. Due to the light weight construction,
Describing each element of the DLE system in more detail and multiple small burners tend to be used, with fuel supply based
referring to Figures 7 and 8 shown earlier: on staging principles. Typically such GT start in diffusion
flame (non-premixed) mode with fuel applied to different fuel
Fuel Control and Combustion “tuning” Gas Turbine Fuels and Fuel Quality
Modern highly efficient gas turbines rely on high-quality alloys
Accurate fuel control is essential for correct gas turbine to allow increased firing temperatures to be achieved, whilst
operation. The gas turbine package comes equipped with a gas still maintaining acceptable product life. To ensure this is
fuel module, complete with all necessary instrumentation, achieved, far more attention on the use of the fluids entering the
safety valves and the main fuel control valve or valves. gas turbine is necessary, including air, lubricating oil and fuels.
On a diffusion flame burner, fuel control is relatively simple: Fuel quality is a major topic of its own, with some of the
fuel is fed to a single ring manifold which is then connected to fundamental requirements associated with fuel quality
all the individual burners, and gas fuel flow into manifold discussed below, along with potential issues associated with
controlled by a single gas fuel control valve. poor fuel quality.
All Gas Turbine OEMs provide comprehensive specifications
However, lean pre-mix systems are often more complicated, covering the fuel quality permitted for use in the gas turbine.
with pilot burners, multiple main burners and the potential need These are used to ensure fuel quality is defined at the onset of a
to vary the fuel flow through each individual burner depending project and throughout the lifetime of the turbine and are
on the gas turbine load. The complexity of the fuel control prepared for good reason. To ensure acceptable turbine
system varies greatly from manufacturer to manufacturer operation is achieved with little or no impact on major turbine
depending on the DLE combustion system, with staged component life, it is necessary to understand fuel composition
combustion systems tending to be the most complex.There is a and the supply conditions in more detail. Identification of
perception that Gas Turbines operating with lean pre-mixing contamination has become particularly necessary as this can
combustion systems (DLE/DLN) suffer combustion stability have a detrimental impact on exotic materials used in turbine
issues with changes in: blading.
Ambient temperature The choice of gaseous fuels as a primary fuel for use in gas
Fuel Quality turbines is dictated by their widespread availability and low
Operating Loads price. Compositions of gaseous fuels can vary quite widely,
affecting exhaust emissions to atmosphere as well as reliability from those taken directly from oil or gas wells which can
of the product. contain high amounts of heavier hydrocarbons, to those
containing non-combustible species (such as nitrogen, carbon
Whilst this was true many years ago GT OEM’s (as well as a dioxide, argon …). In some cases quantities of hydrogen
number of non-OEM control suppliers) use a variety of sulfide may be present, which, left untreated, can produce
methods to minimise the impact of change to ensure sulfur oxides in the exhaust, and, more significantly, can
compliance with local environmental regulations and achieving combine with halides to form compounds which readily attack
high availability and reliability of their GT products. Tuning the exotic alloys used in turbine blading, resulting in premature
has now been replaced with direct control requiring less site component failure.
based manual intervention .
Gaseous fuels can contain a wide variety of contaminants such
It is not possible to describe all methods due to the different as:
combustion systems employed, for example staging, mode Solids
switch between diffusion to full lean pre-mixing etc., but in Water
most cases the control systems used have additional Higher hydrocarbons
methodology included which permits some degree of self- Hydrogen sulfide
compensation or adjustment to ensure a pre-defined map of Carbon dioxide
operation is applied. This ensures the balance of exhaust Carbon monoxide
emissions, NOx and CO, typically, blow-out conditions and Hydrogen
combustion vibration (or dynamics) are maintained to an
acceptable level. The importance of providing a comprehensive fuel composition
in order to determine the suitability of such fuels should not be
However, it is worth considering the system employed by under-estimated. Concerns and issues can be identified at this
Siemens in the light industrial gas turbines products. These early stage to allow preventative measures, such as fuel
products use pilot and main fuel control valves permitting lean treatment, to be taken.
pre-mixing across the full range of load. Rather than having Higher hydrocarbons influence the hydrocarbon dew point, and
pre-defined fixed pilot fuel schedules, this control methodology a high supply temperature is thus required. If the temperature
takes the existing measured operating parameters and is not maintained then liquid dropout (condensate) will result
automatically adjusts the pilot fuel schedule to ensure stable and can cause problems in the fuel system, or, more seriously,
Refinery; Process Off-gas; Hydrogen Syngas There are cases where neither diesel nor gaseous fuels are
Process off-gas, such as a refinery tail gas, can be used as a available or economic to use, and the only suitable “fuel” is
suitable gas turbine fuel. These tend to contain high levels of crude oil. This creates challenges that have to be handled
Hydrogen and sometimes Carbon Monoxide; therefore special through fuel pre-treatment and fuel injection system
consideration has to be made for these types of fuels. functionality {12}. Firstly, heating the fuel reduces the
Syngas also falls into this category, but these are mostly viscosity, but noting the limitations:
derived from the gasification or pyrolysis of coal, petcoke, First is 100°C, at which water boils off (all liquid
various wood types, or municipal or agricultural waste fuels contain a small amount of water) causing
products. These are low in heating value compared to biogas, cavitation in fuel pumps
for example, but comprise Hydrogen and Carbon Monoxide as Increasing fuel oil supply pressure allows the heating
well as quantities of inert species, CO 2 and N2. All of these to be extended beyond 100°C, but is limited by the
need special consideration due to the impact each has on temperature limits within the fuel delivery system
combustor flame speeds and the propensity for “flashback” and Further heating can result in fuel cracking and coking
the resultant damage to combustion hardware. in the fuel system and burners depending on the
Hydrogen-rich fuels have been used with some success, but constituents within the crude oil
require the use of conventional combustion as such fuels tend
to “flash back” in lean pre-mix combustors, with consequential Crude oils need to be treated in order to meet industrial gas
hardware damage. Wet injection can be applied to reduce turbine limits on metallic and other contaminants in the fuel.
atmospheric pollution. A derivative of this capability is gases Crude oil often contains high amounts of alkali metals (Na, K)
produced from coke batteries in the steel making process. Coke and heavy metals (V, Ni, etc.) which if introduced into the
Oven Gas, COG, is high hydrogen, but also contains methane combustion system can result in accelerated deposit formation
and to a lesser extent CO. Conventional, diffusion combustion and high temperature corrosion in gas turbine hot gas path
system is applied but additional gas cleaning is essential to components. Major corrosive constituents include Vanadium
pentoxide (V2O 5), sodium sulfate (Na2SO4) and aggressive low
REFERENCES ACKNOWLEDGEMENTS
1 R McMillan and D Baker, October 2000 There are many colleagues across Siemens Industrial
NOx control in gas turbines - a comparison of approaches Turbomachinery Ltd, whose contribution is recognized
IMechE Seminar S706 - Meeting Limits on Emissions otherwise this paper would have not been possible. The authors
specifically recognize the individual contributions from
2 TI Mina et al colleagues in the Combustion Group, Peter Martin, Victoria
A low smoke dual fuel injector with water and steam Sanderson, Ghenna Bulat and Eoghan Buchanan. Finally, the
injection for industrial gas turbines authors would like to thank Siemens Energy for permission to
Powergen Asia 1997 publish this paper.
3 B Zeldovich et al
Oxidation of Nitrogen in Combustion
Academy of Sciences, USSR
Moscow-Lenigrad 1947
6 K Syed, E Buchanan
The nature of NOx formation within an industrial gas
turbine dry low emission combustor
ASME Paper Number GT2003-38211