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Design Considerations For Heated Gas Fuel: GE Power Systems
Design Considerations For Heated Gas Fuel: GE Power Systems
GER-4189B
GE Power Systems
Design Considerations
for Heated Gas Fuel
D.M. Erickson
S.A. Day
R. Doyle
GE Power Systems
Greenville, SC
Design Considerations for Heated Gas Fuel
Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Gas Fuel Performance Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Gas Compressor Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
General System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Gas Fuel Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Gas Fuel Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Gas Fuel Supply Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Gas Fuel Supply Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Combustion Specific System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
DLN-1 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
DLN-2.0 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DLN-2+ Requirements (PG9351FA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DLN-2+ FB Requirements (PG7251FB & PG9371FB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DLN-2.6 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DLN-2.5H Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Typical GE Gas Fuel Heating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Introduction ature level of the gas at the exit of the gas com-
pressor is a function of its inlet conditions. This
Gas Fuel Performance Heating temperature may vary from site to site and
As the need for higher efficiency power plants should be evaluated against any combustion
increases, a growing number of combined-cycle specific requirements defined in this docu-
power plants are incorporating performance ment.
gas fuel heating as a means of improving overall
plant efficiency. This heating, typically increas- General System Requirements
ing fuel temperatures in the range of
The following section identifies general system
365°F/185°C, improves gas turbine efficiency
requirements that apply to all gas fuel heating
by reducing the amount of fuel needed to
systems. These requirements, in addition to
achieve desired firing temperatures. For fuel
those described in the Combustion Specific
heating to be a viable method of performance System Requirements section shall be followed
enhancement, feedwater has to be extracted during the design and development of the sys-
from the heat recovery steam generator tem.
(HRSG) at an optimum location. Boiler feed-
water leaving the intermediate pressure econo- Gas Fuel Cleanliness
mizer is commonly used. Using gas-fired, oil- Gas fuel supplied to the gas turbine shall meet
fired or electric heaters for performance gas the particulate requirements as specified in the
fuel heating will not result in a power plant latest revision of GEI-41040, "Process
thermal efficiency improvement. Specification –– Gas Fuels for Combustion in
Proper design and operation of the Gas Fuel Heavy Duty Gas Turbines," (Reference 1). If the
Heating System is critical in insuring reliable components in the Gas Fuel Heating System are
operation of the gas turbine. Improper selec- constructed of materials susceptible to corro-
tion of components, controls configuration sion, a method of final filtration upstream of
and/or overall system layout could result in the gas turbine interface is required. Particulate
hardware damage, impact plant availability and carryover greater than that identified in GEI-
41040 can plug fuel nozzle passages, erode com-
create hazardous conditions for plant person-
bustion hardware and gas valve internals and
nel. This paper addresses the critical design cri-
cause damage to first stage turbine nozzles. The
teria that should be considered during the
new gas piping system must be properly cleaned
design and construction of these systems.
prior to initial gas turbine operation. Additional
Also included in this paper is the design of a design considerations related to gas fuel clean-
"typical" GE Gas Fuel Heating System. This sys- liness may be found in GER-3942, Gas Fuel
tem has been developed taking into considera- Clean-Up System Design Considerations for GE
tion the system requirements defined within. Heavy Duty Gas Turbines," (Reference 2).
The Modified Wobbe Index is a calculated Consideration shall be made to the location of
measurement of volumetric energy content of the gas chromatograph relative to the inlet of
fuel and is directly related to the fuel tempera- the gas fuel module and the time delay from
ture and lower heating value (LHV). The instrument reading to fuel gas control.
Modified Wobbe Index is derived as follows:
Combustion Specific System
LHV Requirements
MWI = Tg • SG
The GE Gas Turbine product line incorporates
Where: the use of both Dry Low NOx (DLN) and Non-
Dry Low NOx (conventional) combustion
MWI = Modified Wobbe Index (temperature
designs. Currently, there are five different DLN
corrected)
configurations offered by GE: DLN-1, DLN-2.0,
LHV = Lower Heating Value of Fuel DLN-2+, DLN-2.6 and DLN-2.5H. Each com-
(BTU/SCF) bustion design is applied to one or more gas
turbine models. These designs have different
Tg = Absolute Temperature (°R)
hardware configurations and operability
SG = Specific Gravity of fuel relative to air schemes and in turn have certain contrasting
at ISO Conditions gas fuel heating requirements. Performance
type gas fuel heating is not normally applied to
The ±5% Modified Wobbe Index range insures
conventional combustion systems, and thus will
that the fuel nozzle pressure ratios are main-
not be addressed in this document. Table 1
tained within their required limits. If gas fuel
identifies the combustion designs that are
constituents and heating value are consistent,
applied to the various turbine models. This sec-
the 5% tolerance can be based strictly on tem-
tion will detail the system design and operabil-
perature variation. If the heating value of the
ity requirements that apply to the specific DLN
fuel varies, as is the case when multiple gas sup-
combustion design.
pliers are used, heating value and specific grav-
ity must be considered when evaluating the DLN-1 Requirements
allowable temperature variation to support the On gas turbines that utilize DLN-1 combustion
5% Modified Wobbe Index limit. designs, the Gas Fuel Heating System and sup-
For the use of gas fuels having a significant vari- porting control system shall be designed to pro-
ation in composition or heating value, a per- vide either cold or heated fuel as based on the
manent gas chromatograph shall be furnished gas turbine’s requirements.
in the plant’s main gas supply line. LHV and The gas turbine control system will provide a
specific gravity readings from the gas chro- permissive signal indicating when heated or
matograph are used to regulate the amount of unheated fuel is required. The plant control
fuel heating so that the ±5% Modified Wobbe system shall use this signal to initiate gas fuel
Index requirement is satisfied. This control heating on start-up and to cease gas fuel heating
function shall be performed automatically by on shutdown. For DLN-1 combustion designs,
the plant control system. the fuel shall be in a cold state from ignition
addition, Extended Piloted Premix Mode, from Piloted Premix Mode at approximately 25%
50% load to Baseload, requires the gas to meet load.
the Modified Wobbe Index hot limit.
Permissives set within the gas turbine controls, DLN-2+ FB Requirements
prevent a transfer into the appropriate Piloted (PG7251FB & PG9371FB)
Premix load or Premix Mode, during loading,
On gas turbines that utilize the DLN-2+ FB com-
until the required temperature is attained.
bustion system design, the Gas Fuel Heating
Thermocouples located directly upstream of System and plant controls shall be designed to
the gas turbine’s Stop Speed Ratio Valve initiate provide either cold or heated fuel as based on
this permissive. the gas turbine’s requirements. (See Figure 2.)
During turbine shutdown, gas fuel heating DLN-2+ FB combustion systems are designed to
shall be ceased only after transferring out of operate on heated or unheated fuel in
SPEED
Diffusion and Sub-piloted Premix Mode. During turbine shutdown, gas fuel heating shall
Diffusion and Sub-piloted Premix Mode opera- be ceased only after reducing load below 20%.
tion consists of ignition, acceleration to Full
Speed No Load, and up to approximately 10% DLN-2.6 Requirements
load. (See Figure 2.) During Piloted Premix On gas turbines that use DLN-2.6 combustion
Mode operation, from approximately 15% load designs, the Gas Fuel Heating System and plant
to 20% load, the gas fuel temperature can be controls shall provide either cold or heated fuel
hot or cold. However, the gas must satisfy the as based on the gas turbine’s requirements. (See
Modified Wobbe Index hot temperature limits, Figure 3.)
in Piloted Premix Mode, from approximately
DLN-2.6 combustion systems are designed to
20% to 40% load. During Premix Mode opera-
operate on heated or unheated fuel in Modes 1,
tion, the gas temperature must be sufficient to
2 and 3. Heated fuel operation in Modes 1, 2
satisfy the Modified Wobbe Index limit. In addi-
and 3 is permitted, but not recommended, for
tion, Extended Piloted Premix Mode, from
normal operation. The gas must be heated to
40% load to Baseload, requires the gas to meet
satisfy the Modified Wobbe Index hot tempera-
the Modified Wobbe Index hot limit.
ture limits prior to transferring to combustion
Permissives set within the gas turbine controls Mode 4, at approximately 25% load.
prevent operation in Premix Mode or in Piloted Thermocouples located directly upstream of
Premix Mode until the required fuel tempera- the gas turbine’s Stop Speed Ratio Valve initiate
ture is attained. Thermocouples located direct- a permissive to transfer into Mode 4.
ly upstream of the gas turbine’s Stop/Speed Fuel temperature must be maintained within
Ratio Valve initiate this permissive. the hot gas temperature limits at all modes
SPEED
above Mode 3 (approximately 25% load) dur- tion and piping configuration of the typical Gas
ing both unit operation and shutdown. During Fuel Heating System. This system, as described,
turbine shutdown, gas fuel heating shall be was initially applied to the MS9001H combined
ceased only after transferring out of Mode 4 cycle power plant, which used intermediate
and into Mode 3. The gas fuel temperature is pressure feedwater as the medium for fuel heat-
recommended, but not required, to be less than ing. The design criteria utilized during the
120°F/49°C before transferring from Mode 3 development of this system shall be followed
to Mode 1. during the detailed design of all gas turbine gas
fuel heating systems that utilize feedwater or
DLN-2.5H Requirements steam as the heating medium. Job specific gas
On gas turbines that operate with DLN-2.5H heating systems may deviate from this design
combustion designs, the Gas Fuel Heating based on gas conditions and interfacing bal-
System and plant controls shall provide either ance of plant systems.
cold or heated fuel based on the gas turbine’s
requirements. Design Criteria
The standard Gas Fuel Heating System design
The DLN-2.5H combustion systems are
meets the following design criteria:
designed to operate on both unheated and
heated fuels at ignition through Diffusion ■ Provide heated fuel that meets the
Mode and into Piloted Premixed Mode. The Modified Wobbe Index requirement of
gas must be heated in order to satisfy the the gas turbine’s combustion system.
Modified Wobbe Index hot gas temperature ■ Prevent water from being admitted to the
limits prior to transferring to Premixed Mode. gas turbine combustion system following a
heat exchanger tube leak or rupture.
Typical GE Gas Fuel Heating System ■ Provide early indication of heat
The following section details the mechanical exchanger tube failure.
design and operational features of the typical ■ Prevent gas fuel from entering the feed-
GE Gas Fuel Heating System. The design intent water system following a heat exchang-
of this system is to produce gas fuel that meets er tube failure.
all requirements previously specified in this doc- ■ Remove gas entrained particulate as
ument. In addition to supporting heated fuel to specified in the latest revision of GEI-
the gas turbine, the typical system pro-vides safe- 41040, Process Specification –– Gas
guards that prevent gas fuel from entering the Fuels for Combustion in Heavy Duty
HRSG system. This commonly ignored condi- Gas Turbines (Reference 1).
tion can occur when a tube leak is present dur-
■ Provide overpressure protection to the
ing gas turbine operation or unit shutdown. gas turbine Gas Fuel Heating System
This typical design is provided as a reference to piping and components.
the customer. Deviations from this design may ■ Ensure water pressure is higher than gas
be acceptable, providing that the requirements pressure during gas turbine operation
of the gas turbine are met. and shutdown.
PT
LSHH
A
LSHH
LEVEL 3 B
LEAK DETECTOR *
LSHH
C
LSH
FV
FV
TE FV
PT TE
FV
PI PI
LG LG
IP ECONOMIZER
LSH LSH FV OUTLET
LSH
LV LV ATMOSPHERIC
FV
TE FV TCV
FV CONDENSATE TANK
TE PT
PDSH
FV
COALESCING
FILTER SKID
LSHH
A
LSH LEVEL 1 LEAK DETECTOR *
LSHH
LEVEL 2 LEAK DETECTOR * B
LSHH
FV
C
GAS FUEL
FA HEATER SKID
LSH
temperatures above the minimum superheat The metering tube houses a flow orifice, two dif-
requirement. ferential pressure transducers, three tempera-
ture elements and a pressure transducer. The
As fuel exits the superheater, it enters the
gas turbine control systems read signals provid-
Performance Gas Fuel Heater. This system
ed by these instruments to calculate a pressure
incorporates a stacked two-shell heater arrange-
and temperature-compensated fuel flow.
ment with the gas on the shell side and the
feedwater on the tube side. Each of the heat The typical Gas Fuel Heating System uses inter-
exchanger shells is furnished with low point col- mediate pressure feedwater as the heating
lection sumps. These sumps house level instru- medium. The feedwater enters the Gas Fuel
mentation that provide early indication of a Heater Skid and passes through a double block-
heat exchanger tube leak or rupture and auto- and- bleed valve arrangement to the tube side
matically control the sump drain valves. of the heat exchanger. These automated block-
Activation of a single high level switch indicates and- bleed valves prevent gas from backflowing
detection of a Level 1 leak, while triple redun- into the feedwater systems during unit shut-
dant high-high level switches indicate a Level 2 down if a tube leak is present. A similar three-
leak (See Figure 5.) A full bypass/bypass valve is valve block-and-bleed configuration is provided
provided around the Gas Fuel Heater to allow at the heat exchanger feedwater outlet. The gas
for certain modes of operation when the heat temperature control valve is located directly
exchanger is not in service. Dependent on com- downstream of the second isolation valve.
bustion type and frame size, these “cold”
Component Description
modes of operation may be load and/or emis-
sions limited. (Refer to the Combustion The following section provides a detailed
Specific Requirements.) description of the hardware components within
the typical Gas Fuel Heating System. Unit spe-
The gas fuel exiting the Gas Fuel Heater Skid
cific components may differ based on incom-
enters the gas fuel scrubber. This “dry” scrubber
ing gas conditions, heating requirements and
performs two functions in that it a) provides
over-all plant configuration. The component
the final level of particulate filtration upstream
out-line drawings may differ depending on the
of the gas turbine, and b) removes gas-
equipment supplier:
entrained water droplets present as the result
of a minor tube leak (i.e., pinhole). Two levels Coalescing Filter Skid — The Coalescing Filter
of instrumentation within the scrubber moni- Skid is designed to protect the downstream gas
tor for the presence of liquids. A high level fuel system against the entry of both liquid
switch will generate an alarm and automatical- phase fuel and particulate contaminants. (See
ly open the scrubber drain valve that drains col- Figure 6.) At rated flow, the efficiency of the fil-
lected fluids to the drain tank. Two out of three ter is 100% for solid and liquid particulate larg-
high-high level switches indicate detection of a er than 0.3 microns at rated flow. This skid is
Level 3 leak, thus initiating a signal to trip the not designed to remove large quantities (i.e.,
gas turbine. (See Figure 5.) “slugs”) of liquids.
Downstream of the gas fuel scrubber, the gas The skid, as shown, consists of two 100% gas
fuel supply enters the gas fuel metering tube. flow coalescing filters. Each filter is designed
for performing maintenance without removing fuel flows up to the point where the perform-
the gas turbine from service. Peaking units may ance heater can maintain the temperature.
use a simplex arrangement, where the filter can The heater’s capacity will not maintain the
be cleaned or maintained during unit down super-heat level at fuel flows in excess of this
time. value.
Each filter house contains a liquid collection The heater is an industrial unit designed for
sump. The sump is furnished with a drain natural gas application. A Silicon Controlled
system that automatically removes liquids from Rectifier (SCR) controls the heater. The SCR
the vessel. A high level switch is provided controller maintains a constant differential
to monitor the sump level. (See Coalescing across the heater and over the entire range of
Filter Skid Controls.) (Note: If large quantities gas fuel flows where superheating is necessary.
of gas entrained liquids are expected, a scrub- (Note: Non-electric heat exchanger designs,
ber may be required upstream of the coalesc- i.e., gas-fired or oil-fired, may be used for this
ing filter.) application. The startup superheater requires a
heat source available at gas turbine ignition.)
Electric Startup Superheater — The Electric
Startup Superheater is needed at ignition when Gas Fuel Performance Heater Skid — The Gas
the fuel supply does not meet the minimum Fuel Performance Heater Skid consists of two
required superheat level as defined in GEI- stacked shell and tube heat exchangers in
41040. (See Figure 7.) The heater’s capacity is series, gas and water side isolation valves, vent
sized to provide this temperature rise for and drain valves, and instrumentation required
to support the operation of the gas fuel heater. second stage heat exchanger. The nozzles ori-
(See Figure 8.) The heat exchangers are single ented in this manner prevent water from col-
pass, fixed tubesheet type, and include expan- lecting in the inlet or outlet piping following a
sion bellows on the shell. The heat exchangers tube rupture event.
are mounted on a common base. The heat
Each heat exchanger is furnished with a flow
exchanger is designed for the intermediate
restrictive orifice plate located at the inlet and
pressure feedwater to flow within the tubes and
outlet tube sheets of each shell. This orifice
the lower pressure gas fuel to flow through the
plate controls the amount of water that exits as
shell.
a result of catastrophic tube rupture. This de-
With water pressure being higher than gas pres- sign is required to both minimize the effect on
sure, this configuration insures that gas will not the feedwater system and to limit the quantity of
enter the feedwater system following tube leak water entering the gas stream. The downstream
or rupture. The design of the system incorpo- orifices are non-concentric with the tubes to
rates various safeguards designed to prevent allow draining during shutdown. The Gas Fuel
water entering the gas from being admitted to Heater is sized to accommodate temperature
the gas turbine combustion system. downstream of the heat exchanger and will be
Each heat exchanger is furnished with a drain able to supply the desired temperature for all
pot at one end of the shell. These drain pots operating conditions.
house level instrumentation that provide early It may be necessary to provide an automated by-
indication of tube leak/rupture prior to and
pass system around the Gas Fuel Heater in
during gas turbine operation.
order to satisfy the Combustion Specific
The physical configuration of the heat exchang- Requirements defined in this document. The
er has the gas inlet at the side of the first stage need for this by-pass will depend highly on the
heat exchanger and the outlet at the top of the actual heater system applied to a unit.
Gas Fuel Scrubber — The Gas Fuel Scrubber Drain Tank — The Drain Tank is an atmospher-
provides the final level of filtration directly ic horizontal tank constructed of carbon steel.
upstream of the turbine. (See Figure 9.) The The Drain Tank collects and stores liquids dis-
scrubber also removes water droplets from the charged from the Coalescing Filter Skid, the
gas stream following the event of a heater tube Performance Heater drain pots, and the Gas
leak or rupture. For particulate 8 microns or Fuel Scrubber. The vents from the performance
larger, removal is 100% efficient at the design heater also discharge to the Drain Tank. Due to
flow rate. The performance of the scrubber the potential for collecting both gaseous and
insures that the outlet gas will contain no more liquid hydrocarbons, a flame arrestor is mount-
than 0.10 gallons of entrained liquid per mil- ed on the Drain Tank vent. The tank is mount-
lion standard cubic feet of gas, at the rated flow. ed within a containment dike in order to pro-
The scrubber is furnished with an automatic tect the environment from hazardous dis-
drain system that discharges to the Drain Tank. charges.
The Gas Fuel Scrubber is a vertical, multi- The Drain Tank is furnished with a local level
cyclone, high-efficiency dry-type separator. The gauge and a high level switch. Manual draining
scrubber vessel is manufactured of carbon steel of the tank is required when the level reaches a
and is designed to satisfy the requirements of specified setpoint. If excessive amounts of liq-
Section VIII of the ASME Boiler and Pressure uids collect in the drain tank, they should be
Vessel Code (Reference 3). The outlet flange of analyzed and their origins determined.
the scrubber serves as the carbon-to-stainless
steel interface point for the Gas Fuel Heating System Controls
System. In other words, the piping and valves This section provides a detailed description of
between the scrubber and gas turbine connec- the controls hardware and software associated
tion shall be stainless steel. with the typical Gas Fuel Heating System. Unit
specific controls may deviate from the following figured to achieve the desired gas fuel temper-
descriptions based upon the specific plant con- ature at the heater outlet based on the temper-
figuration. ature differential across the heater. The con-
trols are set to maintain a constant differential
Coalescing Filter Skid Controls — Each of the two
temperature with a maximum temperature
full capacity coalescing filters is furnished with
limit.
a level controller and integral drain valve. The
controller maintains a minimal level in the The constant differential is the difference
sump by continuously opening and closing the between the minimum supply gas temperature
drain valve. Collected liquids are discharged to and the minimum superheat level above
the Drain Tank. A single high level switch mon- the fuel’s dewpoint. All control functions are
itors sump level. An alarm within the plant’s per-formed locally by a dedicated SCR con-
control system will initiate upon activation of troller.
this switch. Each filter is also furnished with a
local level gage. Gas Fuel Heater Skid Controls — The gas temper-
ature controls regulate and monitor tempera-
A high differential pressure switch monitors the
ture of the gas fuel supply to the turbine.
pressure drop across the coalescing filter that is
Temperature elements and transmitters are fur-
in use. Activation of this switch generates an
nished at the gas side and waterside inlets to
alarm in the plant controls indicating that a
the gas fuel heater and on the gas side outlet.
switch over to the clean filter is required. The
Signals provided by these instruments are sent
gas outlet of each filter is furnished with a local
to the control system. These signals are used to
pressure gage.
modulate the flow control valve located at the
Electric Startup Superheater Controls — The waterside outlet of the heater in order to attain
Electric Startup Superheater controls are con- the desired gas fuel temperature.
List of Figures
Figure 1. DLN-2+ (PG9351) fuel heating operational requirements
Figure 2. DLN-2+ FB (PG7251FB and PG9371FB) fuel heating operational requirements
Figure 3. DLN-2.6 fuel heating operational requirements
Figure 4. Typical Gas Fuel Heating System Flow Diagram
Figure 5. Heat exchanger leak detection control scheme
Figure 6. Standard Coalescing Filter Skid
Figure 7. Standard Electric Startup Superheater
Figure 8. Standard Gas Fuel Performance Heater Skid
Figure 9. Standard Gas Fuel Scrubber
List of Tables
Table 1. Combustion design to turbine model cross reference