Category: Turbine Reliability


TTS Power Delivers Successful Commissioning and Start-up in Ohio Power Plant

TTS Power Completes Major Modernization project on Critical Vintage Power Generation Assets

Orlando, Florida – 9-15-21 – TTS Power, an Orlando-based Energy Services Company, recently commissioned a second Gas Turbine Generator Modernization project in Ohio.  The upgrades will enable the plant to deliver critical power to consumers as standby generation during peak load demand, emergencies and transmission line maintenance.

‌Engineers and Technicians from TTS Power (Dave Simmons, Chris Crowell, Andrew Younker, Eliana Herrera, Wyatt Brooks, C.T. Wilson) recently completed and fully commissioned the 2nd of two Westinghouse 191 Gas Turbine Generator Modernization Projects for a public utility in Northwest Ohio. The modernization project consisted of Turbine and Generator control system upgrades, complete gas and liquid fuel system upgrades, and multiple instrumentation upgrade packages. Over the past year, TTS Power designed, built, delivered, installed and commissioned both units successfully and on time.

 

Control Panel Install
Old System Demo
New Human Machine Interface

 

At a time when the energy market is evolving, legacy oil and gas-fired units are held in reserve to meet peak demand for a few hours each day on the grid or in emergency situations.  The benefits of retrofitting and modifying these units far outweigh the alternative of “putting them out to pasture” as an unused piece of equipment.  The goal of the Ohio-based power plant was to make their assets flexible, reliable and available for energy output when called upon.  The TTS team worked for over a year to install and implement upgrades and modifications to the existing Westinghouse gas/diesel turbine rated at 15,730 kW.

The scope of the project included the following upgrades:

  • Turbine control system upgrade
  • Excitation and generator protection upgrade
  • On-site project management of electrical and mechanical sub-contractors

 

Upgrade PS&G Panel
New Speed Pick-Ups
New Fuel Valve

 

Mechanical Upgrades

  • New gas fuel control valve and instrumentation
  • New liquid fuel control valve and instrumentation
  • Liquid fuel flow divider installation
  • Instrumentation cabinet overhaul – new devices and rewire
  • Turbine speed sensor retrofit – added 5 speed pickups for turbine speed and turbine gear speed


TTS Engineers: Andrew Younker (Front) and Chris Crowell (Back)

TTS’s team of technicians and engineers worked on-site at the power plant to make all of the necessary upgrades and modifications within the project scope and deadline. In response to the job completion, the Power Production Superintendent of the City Utilities Company in Ohio said, “We have thoroughly enjoyed having your team upgrade our Westinghouse generators.  They have accommodated all of our needs and brought a great level of professionalism and customer service that I have not seen from many contractors.  Thanks for everything and I would recommend TTS to any of your future customers.”

TTS Power (a service group of TTS) specializes in innovative and high-value-engineered solutions that help clients maintain, upgrade and enhance existing power generation and gas compression assets.  For over three decades, our technicians and engineers have provided comprehensive gas turbine technology expertise to the global energy market.

Power Engineering Solutions include:

Customers interested in TTS’s Power services are encouraged to reach out to TTS for a full consultation and get the power solutions that they need for operational excellence and efficiency.

For more information about TTS, visit https://www.ttsenergyservices.com/.

About TTS Energy Services

TTS provides engineering and construction expertise, for the energy industry, worldwide. The company’s long history and experience providing technical solutions to global energy entities makes it a leader in its field. TTS has successfully managed numerous power and compressor station modernization projects and supplied innovative and unique engineering solutions to challenging problems for our energy customers.  Since 1983, their leadership and engineering teams have provided innovative technologies and engineered high-value solutions to over 450 clients worldwide.

Backing up the grid with Legacy Assets

How the Texas Winter Blackouts are driving the need for gas turbine flexibility and availability

In the wake of the recent Texas Winter blackouts, “winter is coming” takes on a whole new meaning for power generation operators in the ERCOT region. When the power went out across the state in early February, it became clear to Texans, politicians and power generation managers that the Texas energy grid was ill-prepared for inclement weather.

To that end, many questions have arisen about how to back-up the renewable energy sources on the grid as well as provide fast start output from gas turbines and other fossil fuel power generation plants. While not all operators and plants are currently available to provide the much-needed output for the ERCOT region, they can be made available with proven upgrades and modifications to existing assets.

At TTS, we utilize our experience to help operators achieve full value from their existing assets. Our experience is comprehensive and covers all areas of your plant operations. In our latest blog, learn more about how time-tested upgrades and modifications to existing gas fire turbines can generate grid stability and revenue for your plant.

Upgrades and Modifications

In today’s ever-changing energy market, it is critical that your assets are available to run when called upon. Recent events prove how critical our energy infrastructure is, in particular during inclement weather. If the lines are there to transport energy, generators and compressors need to be ready to move it. No asset is obsolete or inefficient during these critical times.

At TTS we drive the Modernization of Gas Turbine assets through a program of Conversions, Modifications and Upgrades. The goal of these modifications is to get more output from an existing gas fired asset. Common high-value upgrades include the following:

Supportive Documentation:

Service Line Cards

High-value Generating Opportunities Webinar

Ways to Take Advantage of High Value Generating Opportunities

Benefits

The application of these technological advances to the existing installed fleet results in many benefits including:

  • Increased reliability
  • Increased efficiency
  • Extended asset life
  • Meeting OSHA and other industry standards for gas turbine operations
  • Reduced Operating and maintenance costs
  • Access to leading technologies in the gas turbine market
  • Engineering expertise with on-site and remote calibration and installations
  • On-time delivery of components and services

Take Advantage of High-Value Generating Opportunities

Making modifications and upgrades to existing assets is usually simple and the cost-benefit equation generally improves significantly. For those looking to learn more about making your gas turbine assets reliable, available and efficient, reach out for a consultation with our team at TTS.

About TTS Power

Since 1983, TTS has provided the power generation industry with quality, cost-effective alternatives to all of the major OEMs, from General Electric to Westinghouse. With over 400 clients worldwide, they have a reputation for integrity and turbine engineering expertise. They offer innovative control solutions, modernization and upgrade services to the mature gas turbine market.

The Benefits of the Dual-Fuel as a Back-up System for Grid Stability

In mid-February 2021, temperatures dropped in the ERCOT region and so did the power grid. While the demand for natural gas and electricity soared, freezing problems affected production at wind farms as well as natural gas wells. Supply could not come close to meeting demand – the shortfall exceeded 20,000 MW at times. These recent weather events have taught us that it is critical to have your gas turbine back-up fuel system ready to go when called upon.

Oil and gas-fired units are held in reserve to meet peak demand for a few hours each day on the grid. Yet, these back-up facilities are increasingly used to meet daily demand as it continues to increase, especially in the ERCOT region. A dual-fuel gas-fired turbine can be made to run on these fuels with minimal conversions and upgrades. Join us in our latest blog as we discuss the advantages of converting a turbine to a dual-fuel system.

 

About Dual Fuel

Single-fuel power stations have to foot considerable running and maintenance costs. However, extending this practice to cope with an increased base load is unsustainable, purely from a financial position, and now there is also added pressure to reduce emissions which is increasing the urgency to find an alternative. Research has shown that dual-fuel systems can lower operating costs while complying with emission regulations.

 

Benefits of a Dual-Fuel System

Although dual-fuel presents challenges, the demand for these back-up systems is on the rise. Dual-fuel systems present many operational benefits:

  • Reduced fuel cost
  • A more immediate solution that building a nuclear installation or a new conventional power station
  • Greater adherence to EPA standards and emissions regulations
  • Lowered maintenance costs
  • Generator availability / grid stability
  • Greater output
  • Small upgrades for increased revenue
  • Increased flexibility

 

What we offer

Liquid fuel systems (primary or back up) can be costly and troublesome to maintain and operate. For decades TTS has been offering support to its clients to help improve the operation and maintenance of these systems, both as single fuel and dual fuel configurations.

  • Electronic valve upgrades
  • Purge system upgrades
  • Check valve and distributor valve upgrades
  • Flow divider upgrades
  • Operational changes
  • Atomizing air system upgrades

If you are being asked to consider installing a back-up fuel system, TTS has completed numerous dual fuel conversions on many types of gas turbines throughout the world.

  • Dual fuel diffusion combustion systems
  • Dual fuel pre-mix combustion systems
  • On engine components and systems
  • Off engine components and systems
  • Water or steam injection for NOx abatement

 

Learn more about our Fuel Systems Conversions Services

Read our blog on improving turbine flexibility and reliability with fuel-systems modifications.

Our team of engineering experts is ready to assist you with your fuel-systems modifications project. If you are looking for a quote on the cost-benefit of a dual-fuel system for your gas-fired turbine, contact our team at 407.677.0813.

Modernization, Reliability and Availability Programs for the FT4/GG4 Fleet

For decades TTS and WWT (Worldwide Turbines) have been offering products and services to gas turbine operators globally.  Now, more than ever, in this changing energy environment, a reliable and flexible asset is paramount.  Together TTS and WWT offer a complete list of programs which can make your unit reliable, flexible and completely independent from the OEM.

Upgrades and Modifications

  • Complete Overhaul / Hot Section of GG4A&C Type Gas Generator and Free Turbine
  • Engine test cell
  • Full engine accessory repairs
  • Field Services (mechanical, controls) / Maintenance Contracts
  • Parts support
  • Engine Exchange program / Engine sales and leasing
  • Fuel Nozzle and Manifold overhaul and repair
  • Control System upgrades / modifications
  • Fuel system conversions (Gas fuel, Liquid Fuel, Dual Fuel)
  • Electronic Fuel Valve(s) Upgrades
  • Emissions Abatement Programs (Water Injection / SCR)
  • Instrumentation and Auxiliary system upgrades and modifications
  • Remote Support and Remote Monitoring

Benefits

Gas Turbine Technology is in a constant state of development and modernization with new materials, components, control techniques and protection systems being continually updated. The application of these technological advances to the existing installed fleet results in many benefits including:

  • Increased reliability
  • Increased efficiency
  • Extended asset life
  • Meeting OSHA and other industry standards for gas turbine operations
  • Reduced Operating and maintenance costs
  • Access to leading technologies in the gas turbine market
  • Engineering expertise with on-site and remote calibration and installations
  • On-time delivery of components and services

Expert, Innovative, Energy Savvy

The demand for energy is not going away any time soon, and gas turbines are a stable, viable source of consistent energy output.  Market factors that are driving the need for gas turbine efficiency and reliability include:  available retired units, low-cost fuel in international markets, and the need for fast-start gas turbines.

Making modifications and upgrades to existing assets is usually simple and the cost-benefit equation generally improves significantly.  For those looking to learn more about making your gas turbine reliable, available and efficient, reach out for a consultation with the teams at TTS and Worldwide Turbines.

About Worldwide Turbines

As an independent gas turbine service company, Worldwide Turbines keeps customers operational.  Nothing is more important that staying online.  They offer customers resources from single component parts to entire engine sections for customers in the gas turbine sector.  Their ingenuity, expertise and agile customer service provide comprehensive assistance to meet the demands and time tables of their customers.

About TTS Power

Since 1983, TTS has provided the power generation industry with quality, cost-effective alternatives to all of the major OEMs, from General Electric to Westinghouse. With over 400 clients worldwide, they have a reputation for integrity and turbine engineering expertise.  They offer innovative control solutions, modernization and upgrade services to the mature gas turbine market.

TTS Remote Support for Combustion Tuning and Troubleshooting

During the COVID-19 lockdown orders, retail sales of electricity to the residential sector were about 9 percent higher than the typical heating and cooling demand. While everyone was at home, electric companies and energy generation facilities had to stay available and ready to respond to the increased demand from U.S. households. In order to keep operations running while considering the health and safety of their employees, many gas-fired turbine power plants opted for remote monitoring and troubleshooting options.

As a leader in innovation, TTS has been offering remote monitoring and support for over 30 years. In 1988, we were the first company to apply remote access systems to support and troubleshoot gas turbine operational failures. In these times of remote work, we want to offer our technical assistance and expertise to our customers through our Remote Tuning System. The TTS Remote Tuning System offers a secure, simple and adaptable remote monitoring system that will provide a high level of remote support to a customer without the need for an engineer or operator to be present on site.
 

Features

The system components enhance administrative flexibility while maintaining a high level of security.

check mark icon   Remote Connectivity Over A Cellular 4G LTE Network

This network operates independent of the client’s network, so secure network barriers are maintained. Alternatively, connectivity can be established by connecting the equipment to a secure network where specific ports are opened to allow remote connectivity.

check mark icon   No Software To Install

The system does not install additional software onto a client’s computers. This design eliminates impact on the client’s computer systems and removes software compatibility issues.

check mark icon   Customizable

Remote Monitoring is highly customizable to fit NERC security requirements.

check mark icon   Pre-Configured Hardware by TTS

Once the system is connected, the 4G LTE router will establish a connection and provide a path for TTS personnel to connect via secure VPN. Via this VPN, TTS will have access to the connected equipment – this can be any combination of two Wi-Fi Webcams, or one KVM-Over IP [Keyboard, Video, Mouse].
 

Two Configuration Options for DLN Combustion Systems

The equipment described above has two configuration options for remote tuning of DLN combustion systems.

1) Utilize the KVM-Over-IP

2) No KVM-Over-IP

check mark icon The remote tuner can connect to the HMI computer to monitor turbine operation and make remote tuning adjustments in real time.

check mark icon The Wi-Fi Webcams can be directed at the CEMS display screen and/or at a stand-alone CDMS display screen (if present).

check mark icon This configuration provides the tuner with all required functionality and data monitoring to remotely tune a DLN system.

check mark icon The Wi-Fi Webcams can be directed at the HMI display and at the CEMS or CDMS display.

check mark icon The Webcams provide the tuner with real-time data monitoring capability required for tuning a DLN system.

check mark icon The customer would need to provide a person on-site, who would be in communication with the tuner via phone, to make the control system adjustments required for tuning, as directed by the tuner.

 

How It Works

TTS Remote Turning Infographic

If remote tuning is being conducted, once the connection is made and tested, the remote tuner and the operator can conduct the proper dynamics checks on the combustion chamber. The Operator can also perform any changes to the fuel scheduling necessary to optimize the efficiency of the combustion system while being observed, in real time, by the Combustion Tuner.

If system troubleshooting is being performed, the connection is established, and the Operator and Remote Technician can begin the troubleshooting process. As in the above, any adjustments and reactions can be directed and monitored by remote experts, in real time.

 

Benefits

With TTS Remote Tuning, troubleshooting is secure, simple and innovative. The system can perform machine oversight, detect trends and issues and provide support. The benefits of this system will save time and money, while increasing efficiency. Here are a few more benefits:

  • Instant Response
  • No travel time or delay associated with a site engineer visit
  • Preventive maintenance
  • Lower the rise of crises and machinery downtime
  • Machine efficiency
  • Lower operating expenses
  • Extended intervals between outages
  • Fewer forced outages
  • Reduced repair time

 

How Can We Help You?

Contact TTS and speak with a specialist to discuss and evaluate your possible opportunities for gas turbine remote tuning and troubleshooting.

Call (407) 677-0813 to speak with a technician today.

Black Start – The Driver is Reliability

The solution is TTS’ Operational Excellence



The United States would face severe economic consequences if there was a serious disruption to the electricity supply. The cost could easily run into billions of dollars. While the likelihood of such an outage is low, the concerns regarding the possibility and impact of electricity blackouts is increasing. The leading concerns? Weather, aging infrastructure and cyber-attacks.Regardless of the cause, there are no yardsticks available to compare the cost of infrastructure investment to the cost of power outages. Just know, that it is all expensive. Add the potential for physical harm and injury to people effected by the blackout and there is no calculation that applies.

What is a “Black Start”?

A “black start” is the process of restoring an electric power station or a part of an electric grid to operation without relying on the external electric power transmission network. Needless to say, it’s a very complicated process. The controls and instrumentation used during a black start must operate dependably and with the utmost precision and speed.

A black start unit is one that can start its own power without support from the grid in the event of a major system collapse or a system-wide blackout. In the U.S., every region within the North American Electric Reliability Corp. (NERC) has its own black start plan and procedures. Each region also designates certain plants as black start units.

TTS Answers the Call

One of these plants recently contracted Turbine Technology Services (TTS) to work with them and other contractors to upgrade the plant’s controls and systems to meet the current technology and reliability standards. Black start operations are conducted in compliance with NERC Critical Infrastructure Protection (CIP) standards. Black start resources are linked to the CIP EOP-005-2 standard, and any cyber asset that is essential to the operation of a black start resource is a “Critical Cyber Asset” by definition, according to NERC.

 

The Scope of the Project

TTS is very proud to be awarded this prestigious project based on TTS’ wide collection of skills and experience. The project’s gas turbine reliability improvement scope description included a detailed engineering design package for all materials to be provided for this project.

Those materials include:

  • Complete Control Building (PEECC) for two (2) units including installation of EPWS equipment and FAT testing.
  • Electrical Equipment
  • Air-Start Compressor Skid
  • Fuel Oil Forwarding Skid
  • Transmitter Panels
  • Cable Tray
  • Conduit and Cable
  • Installation engineering
  • Test packages
  • Connection drawings

In addition, the scope entails the following site installation and commissioning activities:

  • Demolition of Complete Control Room Equipment
  • Equipment Installation
  • Complete project installation and commissioning
  • PEECC
  • Fuel Skid
  • Compressors
  • Fuel Valves
  • Cable Tray
  • Conduit and Cable

TTS is excited to announce that the project is well under way. We’ll keep you up to date on what’s happening both here and on LinkedIn, so be sure to follow us online. You’ll be the first to hear all the latest details from TTS. To Be Continued…

Do you have a project that needs a TTS technical solution?
Contact us to see how we can help you meet your goals for operational excellence.

Breaking News: GE Frame 5PA Upgrade Motivated by Forced Outage Also Works for 6B and 7B-EA

TTS Successfully Converts a Mark V Fuel Control to Electronic Valves

A paper products plant in the Southeast was planning for a major spring 2017 inspection for their Frame 5 with preparations were well underway in October 2016 when suddenly, the unit tripped on high vibration, just as day shift arrived at the facility.

An original Row 2 bucket failed, causing considerable downstream damage. Management decided to begin necessary repairs immediately and to conduct the machine’s third major inspection at the same time.

The Frame 5 cogen unit had accumulated nearly 115,000 total fired hours and 1,500 starts since its commission in 1997. The 24.5-MW (on gas) MS5001PA engine was equipped with a DLN-1 combustion system and capable of dual-fuel firing. It was one of the most advanced Frame 5s in the fleet when it was first installed.

Since its commissioning, the 12 combustion, six hot-gas-path (HGP) and three major inspections typically revealed little beyond normal wear and tear. In fact, few significant modifications had been made to the basic engine in its two decades of service and plant personnel told the editors that the bucket failure was the first major issue suffered by the gas turbine in its lifetime.

Chris Mancini of Mechanical Dynamics & Analysis Ltd was informed of the unit trip and its likely damage shortly after it occurred. He and a superintendent were onsite within two days to assist in damage assessment.

Field service personnel arrived one day after Mancini and the following day, the day shift completed its site and safety orientation, organized tools and work areas and ran power and compressed-air lines as needed. The night shift received its site orientation, set up lighting and began disassembling the unit. The project proceeded at an aggressive pace from that point forward given the black-start cogen unit’s importance to mill production.

MD&A was awarded a turnkey contract for repairs, the major inspections of the turbine and generator, as well as some additional projects including the removal of the liquid-fuel and trip-oil systems.

Because the mill never had success operating on liquid fuel, the most practical solution was to not burn liquid fuel. That decision, made years ago by plant management, was easy given the ready availability of quality gas.

However, oil infrastructure eventually ran afoul of the company’s goal for continuous improvement. It took three shifts to remove liquid-fuel components to conduct a combustion inspection and three to reinstall it before engine restart.

The facility has been performing CIs at 8000-hr intervals so the cost, in terms of labor and outage schedule impact, added up quickly.

The plant engineer was guardedly optimistic about doubling that interval, as promised by the more robust coating applied by ACT Independent Turbo Services Inc, on hot-section parts in its Texan LaPorte shop during the outage. However, this doubling required approval by the facility’s insurer and the coating’s merit would need to be considered.

MD&A was credited with developing a plan to eliminate oil capability, including the fuel-nozzle mods, at less than half the cost estimated by an alternative supplier. It should also be noted that by eliminating the parasitic power associated with the liquid-fuel system, unit output increases by 280 kW.

Issues with fuel valves equipped with hydraulic actuators motivated the mill to replace that equipment with electrically actuated valves when the change to gas-only firing was made. With this upgrade, less gas is burned to produce a given amount of power than with hydraulic valves in the circuit.

Replacing the mechanical overspeed bolt and trip-oil system with an electronic overspeed trip enables operators to now verify trip functionality at 500 rpm without stressing the unit.

 

Converting from Dual Fuel to Gas-Only

The liquid fuel system (LFS) for this Frame 5 included the following subsystems: primary and secondary liquid fuel and purge, atomizing air, and water injection and purge. LFS decommissioning, a first step in the conversion of the unit to gas-only operation included deactivation or removal of all hardware associated with oil supply as well as of equipment in the subsystems noted.

During the forced outage, key components of the LFS were removed, but because of schedule constraints and the physical location of some hardware, it was not feasible to remove everything at that time. Others who have performed similar conversions told the editors it’s important to disconnect/remove components that would consume power when inactive—such as the fuel pump and atomizing air compressor—and simply abandon in place piping that would have no adverse impact on gas-only operations.

The end covers and piping inside the turbine compartment were modified during the outage to reflect elimination of the LFS; Mark V controls software was reconfigured to accommodate the changes made.

 

Checklist of LFS Hardware Removed

  • Accessory-gearbox oil-vapor eductor; a desiccant breather cap was installed in its place.
  • Atomizing-air booster compressor driven by the starting diesel, along with related piping and valves.
  • Atomizing-air pre-cooler and its cooling-water supply piping. Source-air piping from the atomizing-air pre-cooler inside the turbine compartment also was removed.
  • Extraction piping from the compressor to the atomizing- and purge-air subsystems.
  • Gas-fuel purge system hardware.
  • Primary liquid-fuel lines from the flow divider to the fuel nozzles.
  • The accessory-gear-driven atomizing air compressor—together with its drive gear and associated bearings.
  • The accessory-gear-driven fuel pump—together with the electric clutch, coupling, bypass valve, and gear and its bearings.
  • Water-injection piping to the fuel nozzles.

 

Fuel Valve Upgrades

The mill’s Frame 5 was equipped with a combined, hydraulically actuated gas stop speed/ratio (SRV) and control valve (GCV) and gas fuel splitter valve. Recall that the SRV and GCV are independent valves. Gas flows through the SRV to the GCV, which regulates the amount of fuel flowing to the ring manifold serving the 10 combustion chambers. The splitter valve serving on DLN machines divides gas flow between the primary and secondary fuel systems.

Turbine Technology Services Corp was retained to remove the liquid fuel system, as described above, and to replace the existing hydraulically actuated, 3-in. SRV/GCV and splitter valves with new electronic valves from Young & Franklin Inc. Existing gas supply strainers and valves were retained inside the compartment. A 3-in. stop valve was required in addition to electronic primary- and secondary-fuel control valves.

 

The company’s Dave Simmons told the editors TTS has deep experience in this work, having removed liquid-fuel capability on about 50 GE Frame 5s through EAs over the years and retrofitted electronic valves from different suppliers on perhaps 20 machines.

Simmons said elimination of liquid-fuel capability on a non-DLN gas turbine is relatively easy, but experience counts when a DLN engine is involved. This project was unique: It was the first time that a Mark V-equipped DLN-1 machine was converted to electronic valves for fuel control—and it took only four weeks from initial request to startup.

TTS proved it could satisfy project goals by running tests on its reconfigured Mark V simulator. No empirical testing was involved. There were no surprises, Simmons said. The Y&F valves performed the way the company said they would.

He added that an increasing number of plants are investigating conversion to electronic valves and most projects can be justified based on opportunity costs. One of the first things to do, Simmons continued, is to determine the availability of physical space to accommodate the new equipment. This shouldn’t be challenging for non-DLN machines, he said.

Some demolition and installation of the new valves and electrical conduit and wiring are key elements of the physical project. The editors were told that most wiring generally can be reused, excepting old non-DLN units. Otherwise, shielded cable is strongly recommended for use with electronic valves.

Finally, if considering electronic fuel valves for your plant, don’t forget to audit the control system logic file to see if it can accommodate the switch from hydraulics to electric. There was no such issue on this project because of all the liquid-fuel infrastructure removed.

TTS modified the gas control software in the Mark V panel and HMI operator screens and then performed functional and operational tests of the new gas control system.

 

Other Activities Required to Complete the Project

  • Disable piping to the gas control valve for the existing hydraulic- and trip-oil systems. Note that the mechanical overspeed trip was disabled when trip-oil supply to the gas control valve was terminated.
  • Install an emergency-stop pushbutton inside the accessory compartment.
  • Install two magnetic speed pickups and independently connect to the Mark V overspeed “hardware” trip.

To convert the dual-fuel end covers to gas only, the liquid-fuel and water-injection distributors were removed. The tubing runs connecting the distributors to the corresponding five primary-fuel nozzles on each end cover also were removed and caps installed in their place at the openings created. Secondary-fuel nozzles attach to the center of each end cover—their liquid-fuel and water-injection connections were also removed and capped.

 

To learn more about TTS’ dual fuel experience and capabilities for fuel conversions or upgrades, visit our website.

Turbine Reliability is Often Driven by Fuel Quality and Availability

“No one wants to burn liquid fuel in their gas turbine – unless they have to.”

Reliability is always key.

Despite fuel resource limitations or fluctuations, despite increased demand and despite the pressures from environmental compliance, confidence needs to be high that the unit will start and operate well. With that in mind, many utilities will use dual fuel capability as a back-up just in case their primary fuel resource fails in quality or availability.

Some areas of the country face economic and reliability risks due to the weather. Forbes reported that “When it’s below 20°F, each time the temperature drops one degree another 400 MW of electricity is needed.” And, it’s not just about electrical demand – Winter 2014 saw a 20-fold increase in gas prices on isolated, cold days… ouch.

Because much of today’s gas supply comes from shale plays, many operators have seen an increase of liquids in the gas which can cause serious issues for the turbine’s operation (Primary Re-Ignition for example) and the environment. The quality of the supply needs to be monitored closely.

Switching to dual fuel, however, has its challenges:

  • Dual fuel is more complex as indicated by the following schematics.
  • More complexity equates to increases in maintenance.
  • Liquid fuel requires careful selection of the fuel filtration system. GE manual calls for a one micron filter.
  • Fuel quality from long term storage will naturally undergo chemical degradation due to Oxidation and Polymerization.
  • Coking can be an issue. 250oF often cited as threshold for coking, but coking severity is on a temperature / time continuum.

If these challenges didn’t dissuade you, reliable liquid fuel operation relies on the successful operation of numerous control components from multiple systems including: liquid fuel, atomizing air, water, liquid and gas purge and false start drain.

Your O&M program should incorporate:

  • Component inspection
  • Device calibration
  • Component testing
  • System testing
  • Robust startup, operating, and shutdown procedures

Some important takeaways:

  • Monitor and address fuel quality issues.
  • Reduce the potential for coking by reducing temperatures in key fuel system components: Water-cooled check valves, 3-way valves/distributor, and post-shut down purging of fuel from system.
  • Consider upgrading to corrosion-resistant flow dividers.
  • Inspect and test dual-fuel components and systems, particularly in the late fall.

To learn more about TTS’ dual fuel experience and capabilities for fuel conversions or upgrades, visit our website.

Add Operational Versatility for Your Gas Turbine with Fuel Flexibility

Ensure availability to produce power during any situation by adding the capability to burn multiple fuels with Turbine Technology Services.

Gas turbines are one of the leading sources of power generation in the United States, making their ability to produce consistent power crucial at all times. Natural gas is the most popular fuel due to its overall abundance, cost-effectiveness, and environmentally friendly status with modern advanced combustion systems. However, it shouldn’t be the only fuel source. … [Read More]

Turbine Technology Services Corporation Showcases Best Practices in Dry Low NOx Combustion Systems

Mitch Cohen of TTS is scheduled to present on fuel nozzle flow testing and its importance to optimal DLN-2.6 operation in the power generation industry

(ORLANDO, FL) —Turbine Technology Services Corporation (TTS), a full-service gas turbine engineering services firm based in Orlando, Florida continues to make a positive impact in the power generation industry as Senior Systems Engineer Mitch Cohen is scheduled to deliver a presentation on guidelines for DLN-2.6 fuel nozzle flow testing at Greenville, South Carolina on May 21st, 2013. … [Read More]