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50
VOL. 51 NO. 2
INTERNATIONAL
UPGRADING F-CLASS
Roger Ford
Universal Plant Services
Keith Marler
Allied Power Group
Darayus Pardivala
Sulzer Turbo Services
Contents...
Columns
6
26 Power generation
Increasing cost of fuel and U.S. dependence on foreign fuel supplies have not
only renewed interest in conserving
energy, but also in generating electric
power using heat wasted from prime
mover processes.
By David Japikse
22
Industry News
A compressor test facility starts up in
Japan
Remembering Will Hickham
Air compressors help make snow
Emuge Corp. hosts machining
seminar
38
Cover story
16 Upgrading F-class
In the last issue, we introduced corrosion and discussed some of the types of
corrosion. In this issue, we discuss
more
corrosion
mechanisms.
Departments
8
Features
On the cover:
Klamath Cogeneration Plant
Picture courtesy Iberdrola Renewables
www.turbomachinerymag.com
...Contents
Fire & Safety
28 Protecting turbine enclosures
28
Operation &
Maintenance
30 Evaluating intake filters
The gas inlet filtration system protects
the turbine from harmful debris, which
can lead to reduced efficiency and
power, component performance degradation, and blade failures. In this article, five steps are suggested for evaluating a current GT inlet filtration system and determining the need for
improvements.
33
Melissa Wilcox
Southwest Research Institute
Cogeneration
33 Burning blast furnace gas
ThyssenKrupp Companhia Siderrgica
do Atlntico (CSA) is building a new
integrated steelworks near Rio de
Janeiro in Brazil. CSA has selected
Alstoms KA11N2 LBtu combined
cycle plant to provide power for the
plant using waste gases from the steel
making process.
37
Operation &
Maintenance
36 Rejuvenating rusty HRSGs
Combined cycle plants suffer a gradual
decrease in output and efficiency
caused by the buildup of corrosion and
deposits on the fin side of tubes in Heat
Recovery Steam Generators (HRSG).
This problem starts creating a visible
reduction in output after about ten
years of operation.
Q&A
20 The gas turbine aftermarket
Darayus
Pardivala,
President
Americas, Sulzer
Turbo Services,
discusses services
provided by independents.
www.turbomachinerymag.com
KALYAN KALYANARAMAN
TURBOSPEAK
as turbine service pervades this issue
in various ways. The cover story (p.
16) talks about an F-class plant
upgrade performed largely by the
OEM. Maintenance evaluating filters (p.
30), HRSG cleaning (p. 36), Frame 5 (p. 37)
is the theme of many articles and write
ups in the issue. Independents get a fair
share of coverage.
When we talk about independents, the
scene inevitably shifts to Houston a playground of all the majors, as Roger Ford (p.
35) of Universal Plant Services puts it.
Houston is home to more than 20 major
aftermarket companies. The OEMs, too,
have their presence there.
In a moving testimony, Marc Hickham
talks about his father Will Hickham (p. 10),
who, in many ways, was a pioneer in the
non-OEM service of gas turbines. Will set
up shop in Houston after being in
Schenectady, NY. Well, he set up more than
one though, selling them to bigger companies. Will was a pioneer even in that trend.
Its a Houston
cycle, says Keith
Marler of Allied
Power Group. Small
independents start up,
then get picked up by
OEMs.
And
inevitably, after they
are bought over, they
spawn more independents as some people
Keith Marler
who would prefer Allied Power Group
working for an independent do not like the change and start their
own business.
Is this a Texan trait, then? Ford, while
acknowledging the Texan independent
streak, says this is a larger characteristic of
the rotating machinery industry, where individual talent often shines through in spite of
domination by big companies.
Marler says he is still young enough to
grow the business on his own he is 42
years old, but with nearly 25 years of experience. Marlers story gives a fascinating
insight into the values that ensure success.
He started out as a grinder helper and
sand blaster and worked his way up in Preco
Turbine. He started Turbine Blade Repair
G
The spirit
of Texas
Services (TBRS) in 2000, grew the company and, in 2005, merged it with Bruce
Agardys Power Spares to form Allied
Power Group.
He learned engineering at the University
of Life, Marler proudly says, and adds that
he never went to any college. Today, Allied
Power Group employs over 90 people and
recently expanded into a 75,000 sq. ft facility. Now that the new Houston facility is
open, Allied Power Group has closed its
other locations in Houston (17,500 sq. ft.)
and Coconut Creek, FL (6,000 sq. ft.).
Marler believes theres potential for Allied
Power to expand to 150,000 sq. ft.
Those who know Marler describe him as
easy going and very humble. You wouldnt
know he is one of the leaders of a big company if you saw him in a store.
What Marler has instead is a work ethic:
Doing one thing and doing it exceedingly well.
Marlers repair business has been helped
by the trend to repair rather than buy parts,
as users try to cut corners and increase profitability. And Marlers Allied Power Group
specializes in F-class repair, which contributes 70% of the companys business.
Thats the market we were going for
and we had prepared the business plan
accordingly, adds Marler. Sales increased
by 22% in 2009 for Allied Power Group.
Darayus Pardivala of Sulzer Turbo Services
also believes that it is the investment in Fclass that Sulzer made a few years ago that
is paying off now for the company.
Allied Power Group is now looking at
servicing steam turbines, with F-class
combined cycle plants coming up for
major maintenance. Servicing steam turbines, according to Marler, is labor-intensive and users do not always stock spare
parts. He expects a lot of repair happening
on diaphragms due to water erosion, and
packing glands.
Next year, Allied Power will get into the
F-class rotor business. The company currently has agents in Europe and Asia along
with satellite facilities. Sweden and Central
Europe are also target locations.
Houston provides resources for these
companies, as they can leverage niches developed by other vendors, such as laser welding
and EDM. The city is also home to talent
the bottomline, as Roger Ford says. TI
Kalyan Kalyanaraman
Editor-in-Chief
6 Turbomachinery International March/April 2010
www.turbomachinerymag.com
INDUSTRY NEWS
Emuge Corporation hosts
machining seminar
In October last year, Emuge Corp. (cutting tools), Hermle Machine Co. (5-axis
machining), Concepts NREC (CAM software), and M&H Probing Systems
(inspection) hosted a one-day machining
seminar. The seminar focused on new
ways to boost productivity, material
removal rates, and optimize tooling when
machining complex bladed components
such as impellers, blisks, rotors and compressors. The event took place at Emuge
Corp.s technology center in West
Boylston, MA.
Software improves
economizer performance
Economizer supplier, HRST, Inc. (Eden
Prairie, MN), has incorporated Ansys
software in its design and analysis. The
company specializes in equipment that
can withstand fatigue due to cycling. The
software can help HRST perform finite
element analysis inhouse to estimate
fatigue life of components.
in process gas for petrochemical and oil refining plants; associated gas for oil and gas
drilling; natural gas and fuel gas for power generation; and blast furnace byproduct gas
at steel plants. Other emerging markets served by Kobe Steel include CO2 compression.
tion of artificial snow is achieved with this process. A snow system can account for up
to 25% of a ski parks annual operation expense, so selecting the most efficient equipment is critical. Centrifugal compressors are typically the machines of choice in most
snow making systems, due to the fact that this type of compressor typically has the
most economical cfm-per-bhp, compared to rotary screw and reciprocating compressors.
Cameron Compression Systems provides oil-free centrifugal air compressors for
snowmaking applications (Figure 3). Its TA-6000 centrifugal compressor is used in ski
parks, such as Angel Fire Resort, Holiday Valley, Gore mountain and Alpine Meadows.
This multi-stage geared compressor is available in up to 1,750 hp with capabilities of
15 psi and a flow range of 8,000 CFM. Compressed air technology allows ski parks to
realize a longer season by guaranteeing snow showers in the weather forecast.
COVER STORY
UPGRADING F-CLASS
GEARING UP FOR THE FUTURE, KLAMATH COGENERATION PLANT IMPROVES OUTPUT,
EFFICIENCY AND OPERATIONAL FLEXIBILITY
KALYAN KALYANARAMAN
Figure 1: Advanced versions of the F-class introduced by Siemens. These upgrades are designed
so that they can be transferred into earlier models
A clean plant
The Klamath plant is operated by Pacific
Klamath Energy, Inc., an affiliate of
Iberdrola Renewables (IBR). The companys focus is renewables with onshore
wind as the top focus in the U.S. Gas-fired
generation, such as the Klamath plant, is
a flexible resource that complements our
wind generation in the Northwest and
helps us optimize our use of transmission
between the Pacific Northwest and
California, the company says.
Commissioned in 2001, the Klamath
Cogeneration Plant employs two natural
gas-fired combustion turbines and one
steam turbine. A peaking plant of 100
MW in the same location uses four gas
turbines in simple cycle.
IBR manages Klamaths fuel supply
and markets the output of the plants to
wholesale customers in California and
Outage planning
Figure 3: FD3 thermal performance upgrade with row 4
Enabling improvements
One could keep pushing on the gas turbine
performance, but the plant itself is limited
by the Heat Recovery Steam Generation
(HRSG) and the steam turbine, says Ray
Martens, Plant Manager at Klamath. We
studied the balance of plant to evaluate if
they can handle the improved gas turbine
performance, he says and adds, 30 MW
was as far as the HRSG, steam turbine and
condenser would permit. We added a few
banks of radiators to the transformer to
dissipate the additional heat generated by
the higher output.
Klamath Falls winters can be quite
severe, says Martens. We had icing
problems before and, in the past, had to
keep the plant running at a higher level to
avoid ice formation in the inlet.
The inlet heating upgrade (Figures 6,
18 Turbomachinery International March/April 2010
Addressing safety
During the outage, the plant staff became
project managers. While operators performed routine work, the maintenance
department was responsible for managing the contractors. We peaked at 190
people during the outage, says Martens.
Safety is a big concern at these mega
DARAYUS PARDIVALA
Q&A
Can you discuss the
aftermarket trends?
THE GAS
TURBINE
AFTERMARKET
FOCUSING ON
F CLASS
Darayus Pardivala,
President Americas,
Sulzer Turbo Services,
discusses services
provided by independents
Courtesy of IEA.
Figure 2: Despite weaker short- and midterm demand, LNG producers are clearly
planning for the long haul. According to IEA,
gas demand will grow 50% between 2007
and 2030
From subsea
The Gorgon LNG project is to be situated on Barrow Island off the northwest
coast of Australia (Figure 3). It consists
of three 5 mtpa trains and a pipeline to
the mainland.
The project has been in development
for some time, although it has been experiencing delays due to logistics,
approvals and contract negotiations.
Everything was finalized, however,
towards the end of 2009.
GE Oil & Gas will be supplying
propylene and methane compressors for
LNG, as well as a Frame 9 for power
generation and CO2 reinjection technology for carbon sequestration. This LNG
megaproject is just one of many that is
managed by Project Resources
Company (PRC), a division of Chevron
that conducts project management.
Chevron defines a megaproject as one
costing over $1 billion.
PRC is currently managing 17 such
projects worldwide within a portfolio of
60 to 70: five in North America, two in
South America. two in Africa, one in
Europe, two in the Caspian Sea area, four
in East Asia and one in Australia.
Michael Illanne, President and
General Manager of PRC explains the
(Continued on p. 24)
www.turbomachinerymag.com
DAVID JAPIKSE
POWER GENERATION
Applying to geothermal
The U.S. still leads the world in the use of
a plentiful natural resource: Geothermal
energy that can be tapped to convert the
earths thermal energy into electric power.
Such systems can take advantage of the latest design techniques for maximizing the
efficiency of turbomachinery, which is a
major component of these power systems.
For example, the analysis and design of turbine-driven pump units can be quickly performed through Computational Fluid
Dynamics (CFD) and Finite Element Stress
Analysis (FEA) using Agile Engineering,
minimizing design iterations required to
match the operating speeds of the turbine
and the pump.
The basic ORC technology can be
drastically improved over those systems
first prototyped in the 1970s and 1980s
with the availability of advanced computer control systems, advanced materials,
and enhanced CFD modeling of thermofluid analysis. This would not only
increase the overall cycle efficiencies but
also reduce design and analysis costs and
thus improve payback. TI
Note: In the next issue, Japikse will discuss
wind turbine design and carbon capture.
Author
David Japikse is Chairman of the Board,
founder, and CEO of Concepts NREC. Japikse
has written or co-authored
six books: Introduction to
Turbomachinery,
Centrifugal Compressor
Design and Performance,
Centrifugal Pump Design
and Performance, Axial and
Radial Turbines, Advanced
Experimental Techniques in
Turbomachinery
and
Diffuser Performance.
www.turbomachinerymag.com
to equipment, but the risks of these systems can outweigh the advantages. CO2
systems work primarily by removing oxygen. Activation of these systems can be
deadly to personnel, so a delay is required
prior to discharge. This delay can cause
further damage to equipment.
As much as 50% of the time, CO2
systems are ineffective because they have
a definitive hold time requirement and,
typically, turbines are not tight rooms
they have openings. Room integrity is
critical for CO2 systems to function properly. Additional downsides to CO2 systems include high maintenance requirements, inability to cool the room, and the
agents non-sustainable attributes.
The last type of traditional fire suppression system is the clean agent. This
includes two subcategories: chemical and
inert gas. Inert gas systems extinguish fires
primarily through oxygen reduction. They
have limited thermal cooling capabilities
and do not reduce radiative or convective
heat transfer. The fuel is not cooled, and
reignition from hot objects is possible.
Chemical agents rely on flame temperature reduction due to the thermal
characteristics of the agent or disruption
of the combustion process. Similar to
inert gas systems, chemical clean agent
systems do not reduce radiative or convective heat transfer or cool the fuel.
Meanwhile, in 2009, Factory Mutual
established a new category of fire suppression system: FM5580 for hybrid clean
Rapid extinguishing
First, the hybrid system provides uniform cooling to eliminate damage to
motors or controls. Activation of the
www.turbomachinerymag.com
The Victaulic Vortex fire suppression system is a pioneer in hybrid clean agentwater mist technology. The system has
received Factory Mutual Approval for the
protection of combustion turbines,
machinery spaces, and special hazard
machinery spaces in enclosures with volumes not exceeding 127,525 cubic ft
(3,600 cubic m) and a maximum height
Victaulic Vortex emitter
of 24.6 ft (4.9 m). Installations covered by
this approval include:
Machinery space applications such as oil pumps, oil tanks, fuel filters, generators,
transformer vaults and others
Special hazard machinery space applications such as internal combustion
engines or other equipment using fuel and lubrication fluids with volatilities less
than or equal to heptanes and incidental use or storage of limited quantities of
flammable liquids of not more than two 55 gallon (208 L) drums
Protection of combustion turbines in enclosures
three-dimensional total flooding system
results in uniform cooling because the
water and clean agent blend is transported throughout the area and completely surrounds the equipment. The
small water droplets blanket the equipment with minimal to no wetting, and
do not directly impact turbine equipment. With the ability for one emitter to
protect up to 2,500 cubic ft, fewer emit-
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