TurboPHASE: Cost- Effective and Efficient Peaking Power Bob Kraft President & CEO, PowerPHASE LLC Abstract A familiar characteristic of all gas turbines is their inability to maintain constant power output as ambient temperature increases or elevation rises. Consequently, electrical generation and power output are in greatest demand at high ambient temperatures. During a 95 F day in simple- cycle, an F- class machine s air mass flow- rate is reduced by 8% and power reduced by 12% compared to its ISO performance. TurboPHASE provides a constant output of air mass flow- rate into the gas turbine compressor plenum over a wide range of ambient temperatures and altitudes allowing the GT to maintain ISO- like conditions irrespective of temperature or elevation. Figures 1 & 2 below underscore operating characteristics and performance of gas turbines as a function of temperature, as well as market demand for power. Power output with respect to fluctuation in daily temperature Power Output (MW) 500 495 490 485 480 475 470 465 460 455 450 Power Output Temperature 0 3 6 9 12 Hour 15 18 21 100 95 90 85 80 75 70 65 60 55 50 Temperature (F) Cost- effective, fast & reliable peak power solutions remain a premium as owners and operators watch lucrative opportunities to generate a return on their investments diminish as they are unable to meet demands. TurboPHASE, essentially a gas turbine turbocharger, is a fast- implementation solution to both problems. It increases mass flow- rate to the gas turbine via an engine driven compressor, utilizing a single connection to the gas turbine. With a six- month lead time, installation achievable in less than a week and the ability to add 75MW of peak power to a typical 3x1 F class plant in under 60 seconds - operators, owners and investors will find the offering equally attractive from technical, commercial and financial aspects.
Correlation of power demand and temperature Power Demand (MW) 70,000 60,000 50,000 40,000 30,000 20,000 10,000 - Power Demand Temperature 0 3 6 9 12 15 18 21 Hour 100 95 90 85 80 75 70 65 60 55 50 Temperature (F) What is TurboPHASE? The TurboPHASE Module ( TPM, the Module, the System ) is fully mobile, skid- mounted engine- driven compressor used to rapidly and efficiently boost the power output of any industrial gas turbine. Think of turbocharging your car's engine the technology presented here is fundamentally similar. 650 F compressed air exits TurboPHASE at 12lbs/sec, up to 300psi and is injected near the GT compressor discharge. It is offered as a modular package and is the lowest capital cost technology capable of increasing gas turbine output by 20%. The system considerably improves overall plant heat rate in simple cycle configuration, (incremental heat rate is up to 20% more efficient than simple cycle). Applied in combined cycle configuration it produces an almost negligible heat rate increase while producing up to 15% more power from the plant. The TPM measures approximately 30 x8 x8 making it one of the most power- dense solutions available and a perfectly mobile system with minimal auxiliary equipment and a single GT connection. Plant owners, operators and investors find comfort in the TurboPHASE design which avoids risky or unproven technologies by employing the use of well- known and proven OEM components. The System s major components include a 2800HP reciprocating gas engine, gearbox, four- stage intercooled compressor and recuperator. Schematic block diagram of TurboPHASE operating on Combined Cycle plant
TurboPHASE Module Incremental Power possible on typical F- class 1x1 combined cycle 30.0 Incremental Power (MW) 25.0 20.0 15.0 10.0 5.0 - TurboPHASE Inlet foggers Inlet chillers Steam injecmon Duct burners
Incremental Heat Rate Comparison on typical F- class 1x1 combined cycle Incrememtal H/R 16,000 14,000 12,000 10,000 8,000 6,000 4,000 2,000 - TurboPHASE Inlet foggers Inlet chillers Steam injecmon Duct burners TurboPHASE Power Boost for various plants configurations Simple cycle Engine Base power plant 1x1 Combined cycle With TurboPHASE Base power plant With TurboPHASE Output Heat Rate Incr. Output Incr. Heat Rate Output Heat Rate Incr. Output Incr. Heat Rate kw BTU/kWh kw BTU/kWh kw BTU/kWh kw 11N2 13E2 97,919 141,653 10,427 10,186 20,265 19,453 8,352 8,417 144,634 207,954 7,070 6,953 21,425 20,347 6B 34,757 11,340 9,490 9,648 54,533 7,149 10,629 8,016 8,553 7EA 72,585 10,982 16,635 9,748 110,380 7,232 18,617 8,684 7FA 147,082 9,827 23,336 8,333 222,266 6,511 26,417 7,332 9E 107,803 10,602 18,112 9,279 162,597 7,040 19,959 8,386 9FA 219,324 9,735 22,655 8,537 331,221 6,454 26,384 7,309 W501D5A 102,154 10,553 18,831 8,591 152,717 7,070 20,153 8,002 W501F 171,794 9,573 23,631 7,824 253,094 6,506 25,944 7,156 W701F 210,800 9,807 21,863 8,020 305,856 6,759 24,684 BTU/kWh 7,865 7,103 Closing Thoughts Utilities and markets call for additional peak power on hot days to satisfy demand and produce acceptable financial returns to their stakeholders. TurboPHASE replaces unused capacity existent in the gas turbine at simple or combined cycle plants at moderate to high ambient temperatures and/or elevations, allowing the gas turbine to operate at ISO conditions at all times. The incremental power it produces is significant and the incremental efficiency of TurboPHASE is better than gas turbines in simple cycle configuration. When applied to combined cycle plants, TurboPHASE is a more cost effective & efficient source of additional peaking power than any peaking plant in operation. The system is modular, compact, pre- assembled and tested prior to being shipped to the plant so installation is simple, predictable & fast making TurboPHASE an intelligent investment for incremental capacity in today s power generation market.
About Bob Kraft After 15 years in advanced aircraft engine engineering at GE and Pratt & Whitney Bob, with three partners, founded Power Systems Mfg., LLC in 1998 (PSM). Among its first products was a cutting edge ultra- low NOx combustion system for retrofit to GE and Westinghouse gas turbines that reduced engine emissions from 25 to less than 5 ppm NOx. The system is still in service today on dozens of units and still world class performance. After the company was acquired by Calpine in late 2000 Bob remained as VP Engineering succeeding to the presidency in 2008 a year after Alstom acquired the company. Under his technical and business leadership PSM became the world s leading alternate source supplier of advanced components for the state- of- the- art F- class fleet of industrial gas turbines. The company s success was built around Bob s vision of adaptation of aerospace technology to industrial engines and reduced life- cycle cost for fleet owners. PSM also successfully entered both the gas turbine component repair business and the field service business growing sales to more than $100 Million and employment from a handful to well over 300 people. The value of the company was verified by its sale in 2007 for over $242 Million. PSM builds 100% of the replacement parts for 7EA/7FA/501F/6B, among others, giving Bob strong familiarity with the machines as evidenced by the more than 25 gas turbine related patents he s authored and more than 100 credited to PSM.