Co Gen liner upgrade project Jan 2014 Huntsman 6 B conversion to Power System Manufacturing Low emissions combustion system

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Susanna Franklin
5 years ago
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1 Co Gen liner upgrade project Jan 2014 Huntsman 6 B conversion to Power System Manufacturing Low emissions combustion system 1- This Presentation is not to be construed as an endorsement to PSM it is just about our project. Zahi Youwakim

2 PNPP-Utilities Cogeneration C-CG-2 gas turbine combustion system upgrade. Our C-CG-2 gas turbine liners had reached end of life Operating range 59 to 95 deg f ambient Emissions reduction Estimated NOx reduction 85 tons /year, CO reduction 65 tons/year Our permit: 25/25 ppm NOx and CO New Liners <8 ppm NOx, <1 ppm CO Benefits- reliability A reliable combustion system for the next 20 + years. Operating range 20 to 105 deg f ambient Tons Per Year Emission Reduction Nox CO before after

3 Co gen liner upgrade Before - Phase 4 In the last cogen 2 outage the spare set of liners reached its end of life Unit 2 had Phase 4 liners DOB Operating range 59 to 95 deg ambient 2- Emissions 25/25 NOx and CO corrected to 15% O2. Permit we have always struggled to make the 25 / 25 ppm emissions, during colder ambient we have to de-rate machines to stay with in our permit After- with LEC III Proposed: new liners is a replacement in kind 1- Operating range 20 to 105 deg ambient Turn down 100% to 55% load 2- Emissions guaranty 15/15 NOx and CO corrected to 15% O2. 3- The system will give operations a bigger range of operability with out having to worry about out of compliance on emissions. 4-Actual start up after tuning <8 ppm NOx and <1 ppm CO Gas header press at 325 psig (+25 psig). P2 press at 280 psig (+10 psig)

4 Old liners and combustion cans

5 Old gas manifolds and Supports

6 Piping modifications- remove all transfer circuit Gas module Secondary Removed transfer Primary

7 New liners are 6 longer than phase 4 need to evaluate all parts needed and future emissions capabilities OEM DLN-1 phase 6 Conversion. Phase 6 Cap & Liner Assemblies New Cans (combustion casings) Flow Sleeves New can cover with Primary Fuel Nozzles Re use sec fuel nozzles, Stay as transfer system Crossfire Tubes inner and outer Chamber Arrangement Hardware & Consumables New gas fuel hoses New mark 6e controls change New - PSM LEC-III 6B Conversion New low emission Combustion liner kit New PSM low emission Stub Case (Cans) kit New PSM low emission flow sleeve kit New PSM DLN covers & primary Fuel Nozzles kit New PSM low emission secondary fuel Nozzle kit Transfer less New PSM crossfire tubes inner and outer, and clips kit New PSM case drains kit New PSM Primary flame scanner kit New gas flex hoses Mark 6e controls changes and field support

Main differences in Parts-New liners are 6 longer than phase 4 need to evaluate all parts needed and future emissions capabilities OEM Primary can covers- fuel tips with individual orifice total 5

9 Main differences in Parts-New liners are 6 longer than phase 4 need to evaluate all parts needed and future emissions capabilities OEM Primary can covers- fuel tips with individual orifice total 5 per can cover. Liners cooling holes and mixing holes louvers Cowl cap pins (5 each) = angle on the liner Flow sleeves Secondary fuel Nozzle PSM all about pre mix air and gas Primary can covers 1 orifice at the inlet flange. One per can cover Liners effusion holes for better mixing Cowl cap pins (5 each) 67, and 72 deg. Cowl cap can only go one way. Swirl sec flame scanner sight Cooling holes same as OEM Flow sleeves Secondary fuel Nozzle This system is cap of <5 ppm NOx Re-use our old TP s

10 Heated CDP AIR out Forward-flowing Cooled Venturi CDP AIR in

11 Time Temp and turbulence in pre-mix steady state the size of the flame is approx. size of a doughtnut supper lean air to gas ratio (low NOx and CO) New can covers Primary combustion zone /premix Single orifice Sec flame size Sec combustion zone Dilution holes Transfer less sec fuel nozzle Primary fuel nozzles Sec fuel CPD air

12 Flow testing of Sec fuel nozzles to.5% Air flow out of Sec fuel nozzles Gas flow out of Sec fuel nozzles

13 Issues during start up- corrected Secondary flame scanners condensing and UV BFI of range sends a 0 (no flame) to mark 6 Change amplifier for signal strength, install a smaller union with press barrier to shorten the length (SV6) still UV. Install an electric heat trace element on secondary flame scanner lens helped Next is to install new IR2(infrared-favoring) scanners

14 Summary Achievements: Emissions reduction & reliability of new liners NOx reductions 85 tons/year and CO 65 tons/year Machine turn down 55 to 100 % load. Complete conversion: Execution Time: 1 weeks This can be complete during a hot gas path or a combustion inspection.

WET COMPRESSION. What it Is Not. What it Is. Is not traditional inlet air cooling, like a fogger or a chiller

WET COMPRESSION. What it Is Not. What it Is. Is not traditional inlet air cooling, like a fogger or a chiller IGTI 2011 June 8 th, 2011 What it Is 8 to 25% (~12% 7EA) Power Augmentation at any wet bulb temperature above 45 F Complimentary Technology -used in series w/ inlet cooling & other GT upgrades Technology