peter brighton, donaldson australasia: case study: valley power upgrade of air inlet filter house...
DESCRIPTION
Peter Brighton, Australasian Manager GTS, Donaldson Australasia Pty Ltd delivered this presentation at the 2013 Gas Turbines conference. The event is designed as a platform for discussion on the latest technologies & developments in gas power generation. For more information on the annual event, please visit the conference website: http://www.informa.com.au/gasturbinesconferenceTRANSCRIPT
DONALDSON AUSTRALASIA PTY LTD
Valley Power Upgrade – Air Inlet Filter House and Defective Cooling with Peter Brighton
14th Annual Gas Turbine Systems Conference – Hilton Hotel Brisbane 30th October, 2013
INTRODUCTION
• Replace the air inlets and defective fog cooling system of
an existing 300 MW gas turbine plant at Valley Power Vic
• Review the logistics behind the design, manufacture,
quality, delivery and site supervision of the filter houses,
evaporative coolers with structures for 12 Pratt and
Whitney 25 MW gas turbines
• Review the increased summer capacity from evaporative
coolers and the benefits in meeting the guaranteed
performance
Source: www.gsabusiness.com, “GE develops new gas turbine in Greenville” Oct. 30, 2009
Site Issues
• Non OEM fogging system
• Blade corrosion/erosion concerns “ineffective fogging”
• Engine output (Warmer weather conditions)
Source: www.gsabusiness.com, “GE develops new gas turbine in Greenville” Oct. 30, 2009
“A” Station Filter Houses x 6
• Static Filter House
“A” Station Filter Houses x 6
• Static Filter system – 2 stages
- Pocket pre-filter
- Static panel filter
- Fogging “Downstream”
“B” Station Filter Houses x 6
• Static Filter House
• Condition of the Inlet silencer
downstream the filter house.
DOWNSTREAM ISSUES
CUSTOMER REQUIREMENTS
• Expectations
o Guaranteed
pressure drop
o Guaranteed
cooling efficiency
o Deliver and
Commission on
time
Improve Power
Plant Capacity
CUSTOMER REQUIREMENTS
• Design, manufacture,
supply, commission and
performance test.
o 6 x A Station Static
Filter Houses with
support structure
o 6 x B Station Static
Filter Houses with
support structure
o 12 x Evaporative
coolers
o 12 x Transition ducts
o 12 x Stairs and
access platforms
CUSTOMER REQUIREMENTS
• Considerations
o 2 separate
designs
o Existing site
services
o Engine removal
beam to support
structure for B
Station units.
CUSTOMER REQUIREMENTS
• Guarantees
o Cooling
efficiency - 88%
o Pressure Drop
1.5” w.g.
o Delivery 4 x “A”
Station and 2 x
“B” Station Sept
2009
o Delivery 2 x “A”
Station and 4 x
“B” Station March
2010
The Program
Main Task Sub Task Due Date Who
Sign Contract Day 0 Customer
Site Survey 17-03-2009 to 24-03-2009 DAPL
Equipment Design Preliminary GA Station A&B 6/04/2009 DAPL Preliminary P&I D 6/04/2009
Review +5 days after submission by Don. Customer/OE
HAZOP Study Participate 23-03-2009 Customer/DAPL/OE3
Report 27/03/2009 OE
Installation Manual High Level Preliminary 01-04-2009 DAPL
Equipment Design Final GA Station A&B +7 days after review of preliminary
by customer
DAPL
Review and accept +5 days after submission by Don. Customer/OE Foundation and loadings 18/05/2009 DAPL
Control Box Diagram 1/06/2009 DAPL
Quality QCIP/ITP 20/04/2009 DAPL
Review and accept +5 days after submission by Don. Customer/OE
Installation Manual Final 15/07/2009 DAPL
Review +5 days Customer/OE
O&M Manual Preliminary 29/06/2009 DAPL
Review +5 days Customer/OE
Final 11-11-2009 DAPL
Review +5 days Customer/OE
Delivery5
Program U5 Filter Houses (2-off) 1/09/2009 DAPL
U1 Filter Houses (2-off) 1/10/2009 DAPL
U2 Filter Houses (2-off) 1/10/2009 DAPL
U3 Filter Houses (2-off) 1/03/2010 DAPL
U6 Filter Houses (2-off) 1/03/2010 DAPL
U4 Filter Houses (2-off) 1/03/2010 DAPL
Commissioning and Testing U5 Filter Houses (2-off) not later than 27/10/2009 DAPL
U1 Filter Houses (2-off) not later than 26/11/2009 DAPL
U2 Filter Houses (2-off) not later than 26/11/2009 DAPL
U3 Filter Houses (2-off) not later than 26/04/2010 DAPL
U6 Filter Houses (2-off) not later than 26/04/2010 DAPL
U4 Filter Houses (2-off) not later than 26/04/2010 DAPL
Design
• Donaldson Europe Belgium.
o Complete design of the filterhouse and evaporative cooler system
Position of Manufacture
• Donaldson China Shekou
o GDS Filter House
o Evaporative Cooler structure and sump
o Hoppers
Donaldson China Chengdu
o Transition Ducts
o Support Structure
o Access Stairway and Platforms
Position of Manufacture
• Europe (Belgium)
o Control Panel
o Flow gages, sensors, ball valves,
EVAP plumbing
o Electricals, lighting etc, cable trays
o Junction Box
o Pump
o Bellows TD – Inlet.
o EVAP Distribution Panels
Position of Manufacture
• Australia (Wyong NSW)
o Filter Elements
QUALITY INSPECTION
• POM Inspections by Customer – Shekou and
Chengdu
o Material specifications and certificates ITP
o Dimensional Measurements
o Welding
o Paint
o Packing
o Contract
Ensure fit per designed tolerances keeping
any rectification work to a minimum
PRE “TRIAL” ASSEMBLY
• Shekou China
o GDS Filterhouse
o EVAP Section
o EVAP Sump
• Chengdu China
o Transition Duct
o Support Structure
DDP FREIGHT TO SITE
• All China freight consolidated in Shekou
o 72 x Open Top 40ft containers
o 36 x 40ft GP
• Belgium Critical components
o 6 x 40ft GP
Total 72 Open Top and 42 Gp’s delivered by side
loaders to site. Additionally 6 x 40ft GP’s from
DAPL for the filter elements and Evap media
Pads
DEMOLITION AND CIVILS
• Removal of old equipment was
contracted to others
• All Civil works were carried out by the
customer prior to installation of the
support structure
DELIVERED
• Components delivered at laydown area
near Valley Power.
• Some pre assy was required at the
location
INSTALLATION
Support Structure
• The support structure was erected prior to
removing the old units
• Stair and platform access was then lifted
in place allowing for service areas during
lifting of the modules
INSTALLATION
Support Beam
• Note the Beam on the
support structure for
the “B” Station units -
this allowed for the
removal of the engine
utilizing the Donaldson
support structure.
• All load ratings
calculated by
Donaldson Europe to
accommodate
additional weight to
remove the GT.
INSTALLATION
Module Assemblies
Each section was lifted separately
• Sump
• 3 x Evap Sections lifted separately on to
the sump
• Inlet Silencer by others
• Bellows (TD – Silencer)
• Transition Duct (After pre assy at ground
level)
INSTALLATION
Filter Section and Weather
Hoods
• Pre Assy of weather hoods
and bolted to Filter section at
ground level
• As with the EVAP there were
three lifts for the Filter Module
sections
• Note EVAP media and drift
panels not installed.
INSTALLATION
Plumbing
• Installation of the
pipework, pumps,
flow valves etc for
EVAP cooler
• Installation of pump
and connection of
services.
INSTALLATION
Electrical Kit
• Control panel
• Junction Box
• ΔP Filter Section
• ΔP Evap Section (Absolute)
• ΔT Inlet air temp
• Conductivity (Water Quality)
• Internal Lighting
INSTALLATION
Filter Elements
• Upstream Filter elements Installed
Evap Drift Pads and Media
• Evap media installed last ensuring no
damage is caused during the installation
stage
WHAT WENT WRONG
NOT A LOT
• Stairway Handrails not to Australian
standard
• Reduced wall height of Evap dam
walls due to turbulence.
• Access door locks
WHAT WENT RIGHT
A LOT
• Cooling efficiency -
88%
• Donaldson met the
required efficiency
• Pressure Drop 1.5”
w.g.
• Pressure Drop was
measured below the
required 1.5” w.g.
• Delivery was to the
program
PERFORMANCE
Summer Capacity
• Increases confirmed to be approx 4-5MW per GT
• Total 50-60MW across the plant.
QUESTIONS?