Combined Cycle Power Plants Course
Operation, Maintenance and Planned Optimization
| January 16, 2007 |
| 8:30am |
Registration & coffee |
9:00am-5:00pm |
Course |
| January 17-18, 2007 |
9:00am-5:00pm |
Course |
| January 19, 2007 |
9:00am-3:30pm |
Course |
DAY 1
Overview of the Major Plant Equipment
This overview consists of all the major pieces of Equipment in the Power Plant from a mechanical and Performance point of view. An overview and survey of the TurboMachinery (Gas Turbines, Steam Turbines, and Boiler Feed Water Pumps), covering both mechanical and performance aspects are discussed. The selection and major characteristics of the rest of the plant equipment such as the Heat Recovery and Steam Generating (HRSG) systems, the Feed Water Heaters, and the Condensers are also included. The selection of the equipment, the plant layout, environmental considerations, and arrangement, including general mechanical and aerothermal characteristics of all plant equipment are discussed in detail.
Various ASME, API, and other Codes covering all the major equipment will be discussed. An emphasis is placed on specifying and designing for maximum reliability.
Cycle Analysis of the Combined Cycle Power Plant will be undertaken and optimization of the cycle based on the performance of the various components will be studied.
DAY 2
Major Equipment
Advanced Gas Turbine Technology
In this section, various types and sizes of gas turbines used in the petrochemical industry are discussed, along with their classifications by size and application. Comparison is made between industrial and aircraft derivative type of gas turbines. Methods of increasing cycle efficiency and the output power are also discussed. An overview of fuels and materials considerations will be made. State of the art developments in gas turbine technology will also be reviewed. High temperature turbines, closed cycles and other developments are covered.
Axial Flow Compressors and Turbines
Key aerothermodynamic considerations are covered including cycle analysis of gas turbines and centrifugal compressors. Gas turbine performance calculations will also be covered. This section also covers mechanical, performance and aerodynamic aspects of gas turbines. Radial inflow turbines are also discussed. Practical aspects related to gas turbines is emphasized in the discussion.
Combustors, Materials Coatings and Fuels
A description of combustor types, chamber design, fuel atomization, ignition and combustor arrangements are presented. Metallurgical aspects of gas turbine blading, turbine wheel alloys, future materials and gas turbine coatings are discussed. The stress-time behavior of materials is also covered. Common failure modes and cases are presented. Sulphidation properties, specifications, fuel treatments, and heavy fuel operation is discussed.
Coatings as applied to both the Hot Section Components and the Compressor will be discussed from both a life and performance point of view.
Fuels
Discussion on various types of fuels will be conducted from Natural Gas to Heavy Fuel Oil to Low Btu Gas. The behavior of the Gas Turbines on these different fuels will be studied as to their effect on gas turbine performance including the effect on gas turbine compressor surge and on the Heat recovery unit as well as on duct burners if used in the system.
Day 3
Steam Turbine Technology
The design of the Steam Turbines will be undertaken in this section. The design of the High Pressure Turbine, which is usually an impulse turbine, will be discussed and the IP and LP turbines, which are usually reaction turbines, will also be studied separately
HRSG Technology
The study of the HRSG will be undertaken in conjunction with the Feed Water Heaters, Dearators, and Economizers, Plus the Preheaters, Evaporators, and Superheaters of each stage. A study of the Temperature distribution as a function of the Heat input is also studied with various optimization techniques to assure maximum effectiveness of the HRSG.
Condensers
A study of the Condensers and the computation of the degree of fouling will be examined. The study will include techniques of computing the fouling in the tubes and the quality of the steam entering the unit. The effect of the fouling on the condenser pressure and the effect of that pressure on the entire Power output of the plant.
Feed Water Pumps
The design characteristic of the feed water pumps will be undertaken. Most of these pumps have centrifugal impellers and so a study of the flow in these impellers will be conducted and the performance characteristics of these pumps will be studied.
DAY 4
Power Plant Performance and Optimization
The study will include the computation of the deterioration of the various components, of a Combined Cycle Power Plant.. Performance computations will be as per various ASME PTC Codes. The performance analysis of a combined cycle is complex. Most new combined cycle plants operate at very high turbine firing temperatures. Thus variation in this firing temperature significantly affects the performance and life of the components in the hot section of the turbine. The compressor pressure ratio is high which leads to a very narrow operation margin, thus making the turbine very susceptible to compressor fouling.
The performance of the combined cycle is also dependent on the HRSG and the steam turbine performance. The steam turbine is dependent on the pressure, temperature, and flow generated in the heat recovery steam generator.
Performance analysis is not only extremely important in determining overall performance of the cycle but in also determining life cycle considerations of various critical hot section components. Techniques of determining the life of these components will be discussed
MAINTENANCE
Maintenance Cycles of the Gas Turbine, and other components of the Combined Cycle Power Plant are discussed. Maintenance techniques using borescope and spectrum analysis, including acoustic monitoring are discussed. Techniques for checking and conducting repairs on impellers, diffusers, bearings and foundation repairs are emphasized.
Case Histories
Case histories of various types of failures encountered in a Combined Cycle Power Plant are discussed. Participants are encouraged to submit their own failures and other problems so that these may be further analyzed. Participants are encouraged to participate in discussions.
| Organized by: |
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in association with
The Boyce Consultancy LLC |
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