Output and Efficiency Increase on Installed

Gas Turbine Sets

Consideration of involved Risks its Mitigation and Associated Costs on
Electrical Power Equipment






























Contents
1. Task ................................................................................................................................3
2. Summary .........................................................................................................................4
3. Overview of Electrical Components ................................................................................5
4. General Solution Finding Process ....................................................................................6
5. Electrical Components .....................................................................................................7
5.1 Generator ......................................................................................................................7
5.2 Excitation .....................................................................................................................9
5.3 Generator Leads / Bushings ..........................................................................................9
5.4 Current Transformers / Voltage Transformers ...............................................................9
5.5 Generator Bus bars...................................................................................................... 10
5.6 Generator Breaker ....................................................................................................... 10
5.7 Transformer ................................................................................................................ 10
5.8 Protection Systems ...................................................................................................... 11
6. Conclusion .................................................................................................................... 11



1. Task
It is foreseen to provide an overview of the risks and the associated mitigation costs
for the electrical key components:
For the analyses a 7EA GT in single cycle operation is considered:
a) GT Power Output at ISO-Conditions: 82,3 MW
b) Performance at Sea Level and 120F/49C Ambient: 65,8 MW
In order to increase the performance to or above ISO-conditions the installation of six
TurboPHASE Modules is envisaged with a theoretical power output of 83,3 MW
which represents a theoretical power increase of 26 % to the ambient performance
mentioned above.
Provided the voltage level of the Generator will remain the same as well as the
electrical functionality within the limits of the power chart, a Stator Current Increase
of about 20% percent must be considered (the typical Generator Terminal Voltage
Levels on the targeted GT fleet in Middle East Region are 11 kV, 13,8 kV, 15 kV).
The increased current will bring two main tasks*:
a) Leading Higher Current and
b) Handling the Higher Temperatures cause by the higher current
*The generator capability of handling the higher magnetically flux in the core is
defined by its design and assumed to be provided as most Generators handle ISO
condition outputs already in winter time.
2. Summary
Generally the electrical components can be split into two categories:
a) Standard and
b) Non-Standard.
The Standard items can be seen as standardized globally by its OEM irrespective of
the location, the ambient conditions and do have a design capacity according to ISO
Standards, i.e. Generator Stators, Generators Rotors, to some extent oil cooled
transformers (who capacity wise are following the Generation Equipment).
The Non-Standard items have been adapted to serve the ambient conditions (Coolers,
Heat Exchangers, Pumps and Drives) and handle the electrical power at these ambient
conditions (Excitation/ Exciters, Generator Breaker, Bus Bars and Leads, CTs/VTs).
The detailed considerations, which will follow this summary, lead to the below chart
in which a risks and associated costs are simplified presented.
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Figure 1: Risk/Cost Overview
3. Overview of Electrical Components
The Electrical Power Components on a turbine set which need to be reviewed in case
of an upgrade can generally be summarized as follows (refer to figure 2):
1. Generator
2. Excitation / Exciters
3. Leads / Bushings
4. Current Transformers / Voltage Transformers (CTs / VTs)
5. Bus Bars
6. Generator Breaker
7. Transformer
8. Protection Systems
Figure 2: Electrical Components Overview
4. General Solution FindingProcess
For all above named components individual considerations have to be carried out
according to below simplified chart.
Figure 3: Solution Finding Process Flow
5. Electrical Components
5.1 Generator
As most of the generators are designed to operate in ISO conditions (this is easily
confirmed by consulting the manuals and name plates), their design capability is given,
i.e. a 7EA generator is able to handle 82 MW and its related current.
The electrical output of a generator in the above set-up is depending on the temperature
around its main components, i.e. Stator Bars, Rotor Coils, Iron Core and the capability of
transferring this heat away from it. This temperature is generally named Cold Air / Cold
Gas / Cool Air temperature and is defining the temperature inside the generator before
touching the main components (refer to figure 4).
Figure 4: General Cooling Scheme inside Generator
Further, the cold air temperature is the temperature at the downstream side / discharge
side of the Generator Coolers whereas the Hot Air/ Hot Gas temperature is measured
when the Air/Gas flow has passed already the main components (refer to Figure 4).
Depending on the two main cooling configurations
a) Open Ventilated - OV
b) Total Enclosed Water to Air Cooling - TEWAC
the hot air is discharged outside the Generator (a) or into the upstream side of the
Generator coolers (b). It has to be mentioned that Hydrogen Cooled Generators (i.e. 7FH
etc.) are operating in the enclosed configuration.
The Cold Air Temperature is hence to be understood to be kept stable irrespective of the
ambient temperatures which is a function of the cooler capacity which again depends on
the cooling water inlet temperature, the cooling water flow, etc. The cold air flow through
the coolers is not to be changed as it is defined by the ventilator on both sides of the
generator rotor (refer to figure 4) and would need expensive reverse engineering.
Example:
A 7EA GT operating in simple cycle is coupled to a Brush Generator with below design
capabilities (refer to figure 5). For providing the electrical output equivalent to the GT
output as per ISO conditions of 82 MW, the cold air temperature (cooler discharge
temperature) need to be maintained at around 25C/77F, irrespective of the ambient
conditions.
Figure 5: Diagram of a Frame 7 Generator, BRUSH made
In case the cold air temperature is not maintained at the same level, as a result the hot air
temperature increases and can run into alarm and trip level. Changing these temperature
settings to a higher value is not recommended and normally not considered as a solution.
Solution:
As the cooling systems and especially the balance of plant with its different configurations
may differ from site to site, the suggestion is to build a database based on current and yet
to gained site set-up know how. This database provides a standardized approach for each
plant by adapting different measures such as (Fin Fan Coolers, New Pumps, Pre-Coolers,
etc). As an input base to such database a simple questionnaire should be used giving
information about respective parameters (water temperature, water flow, cooler
nameplate, pump nameplate, etc). The questionnaire can be used by sales force when
visiting side or by sending to the customer. As per my experience as long as the customer
sees the generator is operating within in the manual provided charts and diagrams, he is
assured the Generator is safe. In case of design and reverse engineering inside the
Generator, the whole picture changes and the OEM is requested to approve, which should
be avoided.
5.2 Excitation
In order to provide a higher power output, the generator current has to be increased. By
ramping up the rotor current (also known as field current or excitation current) the rotor
field will be more intense which leads to a higher generator current.
The increase of the excitation current is proportional to the power increase. The Exciter
components anyhow are considered to be designed to handle the output as GT Output per
ISO conditions and its related current.
Solution:
The nominal Field Current requested for the respective generator output is provided with
the manual and datasheets in the customer documentation. These values have to be
checked with the nameplates and data sheets of the electrical components. In the rare case
of the excitation will not be able to handle the output, several components have to be
changed (entire exciter, Thyristors). A questionnaire can be provided by requesting all
these information and a database be maintained.
5.3 Generator Leads / Bushings
The Generator Leads or Bushings are the links between the Generator Stator and the bus
bars and are made of flexible design (copper braids or laminated links). Depending on the
Generator type these links are cooled by the same air flow already described in the
generator section.
Solution:
The Generator Leads are designed to handle the Generator current at its designed value,
which is considered to be the GT output at ISO conditions. The links are subject to air
cooling flow inside the generator; hence the same logic applies here as described on the
generator section. Anyhow, the leads can be easily replaced by ones with bigger cross-
section in case required.
5.4 Current Transformers/ VoltageTransformers
The current and voltage transformers are installed at several places on the electrical
periphery and measure the electrical currents and voltages of different levels. The high
current or high voltage (i.e. 5,000 A AC and 13,800 V AC) of the generator leads are
transformed to a lower value (i.e. 1 or 5A AC and 100 120 V AC) and these values
transferred to the systems such as protection, synchronization, excitation, TGC and
metering cubicle for governing and controlling a safe operation.
Solution:
Same as the generator leads, the CTs and VTs are designed to handle the Generator
current at its designed value, which is considered to be the GT output at ISO conditions.
Their real capability can be easily confirmed by consulting the nameplates and data
sheets. In the rare case the CTs are not dimensioned sufficiently, they can be replaced on
the generator as well as on the transformer side.
5.5 Generator Bus bars
The Generator bus bars are leading the electrical power from the Generator to the
Transformer. The bus bars are massive copper bars which are enclosed by a pipe-like
housing on its entire length. The bus bar housing is in some cases slightly over
pressurized in order to keep humidity and dust away and outside.
Solution:
The bus bars are designed to handle the Generator current at its designed value, which is
considered to be the GT output at ISO conditions. The capability of the bars can be
confirmed by manuals or nameplates. The capability of handling higher current is defined
by either the cross-section of the bar or by the ventilation of the bars in case the cross-
section is not sufficient. Considering an adaption, ventilation would be the more
economical solution.
5.6 Generator Breaker
In some of the power stations a generator breaker is installed between the generator and
transformer. The other set-up is to connect the GT-set to the grid by only the breaker on
the HV-side of the transformer without any disconnection between the generator and
transformer. The set-up without Generator breaker is mainly found power stations
operating in simple cycle, where only one generator is connected to the transformer.
Solution:
The generator breaker is designed to handle the generator load which is considered to be
the GT output at ISO conditions. The capability of the breaker can be confirmed by
manuals or nameplates. The generator breaker is an enclosed system and need to be
replaced in rare case it is not be able to handle the load.
5.7 Transformer
Transformers in power stations are normally considered as oil cooled and are designed to
at least the current maximum output the GT delivers at ISO conditions.
As already mentioned in the generator section, the oil running through the inside of the
transformer has to have a certain temperature to handle the losses represented as heat.
The oil is in forced to run through radiator banks (heat exchangers) which are installed
outside the transformer housing where a set of ventilators is established in order to
enforce the cooling through the heat exchangers.
Solution:
The capability of a transformer is to be confirmed by name plates or datasheets available
to the customer. As the temperature inside the transformer (enclosed system) is
depending of the convection of the installed radiators / coolers, there are certain measures
that can be adapted when transformer reaches its capacity limits, including forcing the
convections by ventilators of different size, increasing the number of coolers / radiators
or using different cooler types, such as water to oil coolers.
5.8 Protection Systems
The protections relays are governing and controlling the electrical operation of the
generator and transformer and using the signals given by the CTs and VTs. As the VTs
and CTs secondary side current is predefined and will not exceed the maximum limits
(i.e. 5 A AC or 120 V AC), the panel and electrical cabling are not to be considered risky
neither are the inputs for the protection relays.
Solution:
Generally, the protection settings are to be set according to the designed value of the
generator. It can easily be checked by consulting the commissioning or service reports and
can be changed in case required.
6. Conclusion
Provided the components that lead current are sufficiently designed for handling the
current which is driven at ISO conditions, the main task is to compensate the heat
increase which is caused by the higher ambient temperature.
The risk, perceived by the customer, can be minimized by operating the generator per the
OEM guidelines and increasing the heat exchanger capability as required. This will
require site specific application engineering.