1. Gas Turbine Technologies: Fuel Flexibility & IntegrationGas Turbine Technologies: Fuel Flexibility & Integration
Shima shahali
Oil & Gas Product Development Coordinator
Mapna Group Co.
3 June 2015
1

2. Outline
1. Introduction
2. Combined Cycle Power Plant (CCPP)
3. Fuel Oil Treatment Plant (FOTP)
4. Mapna Gas Turbine Technologies
5. Case study: Kermanshah Power Plant /Iran
6. Result
7. Recommendations (Reco’s)
2

3. Standard Natural Gas 39 to 46 MJ/kg)
Gasoil 42 MJ/kg
low‐BTU gases 10 and 35 MJ/kg
Syngas 4 and 12 MJ/kg
1‐ Introduction
2‐Combined
Cycle Power
Plant
3‐ Fuel Oil
Treatment Plant
4‐Mapna Gas
Turbine
Technologies
5‐ Case study
6‐Result
7‐ Reco’s
Introduction
3

4. Characteristics of Untreated HFO
•High viscosity
•High density
•Cat fines
•High salt content
•High vanadium content
Characteristics of Treated HFO
•Heating of HFO is required up to 120°C
•Two stage washing system is required
•Wash water addition of up to 10% of
fuel flow
•Wash water heating is requested
•Chemical dosing (demulsifier, inhibitor,
etc.) requested.
Protect
Our Gas
Turbines
4
1‐ Introduction
2‐Combined
Cycle Power
Plant
3‐ Fuel Oil
Treatment Plant
4‐Mapna Gas
Turbine
Technologies
5‐ Case study
6‐Result
7‐ Reco’s

5. Mechanical BOP
 NG & Gasoil Fuel System
 Gas & Liquid Fuel Specification
GT Limitations
5
Combined Cycle Power Plant Index
1‐ Introduction
2‐Combined
Cycle Power
Plant
3‐ Fuel Oil
Treatment Plant
4‐Mapna Gas
Turbine
Technologies
5‐ Case study
6‐Result
7‐ Reco’s

6. Mechanical BOP for one Block
A.Gas & Liquid Fuel System
B.Compressed Air System
C.Fire Protection System
D.Nitrogen System
E.Crane, hoist
F.Heating, Ventilation and Air Conditioning
G.Water Treatment System
H.Waste Water and Sewage System
I.Auxiliary Boiler
6
1‐ Introduction
2‐Combined
Cycle Power
Plant
3‐ Fuel Oil
Treatment Plant
4‐Mapna Gas
Turbine
Technologies
5‐ Case study
6‐Result
7‐ Reco’s

7. NG & Gasoil Fuel System
Consumer Qty
Pressure
(bara)
Consumption
(kg/sec)
Gas Turbines 2 21 ± 2.5% 24
HRSG 2 4‐5 1.8
Auxiliary boiler 1 4‐5 0.4
Admin Mechanical room 1 3.5 0.023
Canteen Building 1 3.5 0.05
Total NG Consumption for 1 Block CCPP 26.27
7
Consumer Qty Pressure
Consumption
(kg/sec)
Gas Turbines 2 2.5‐8 bara 22
HRSG 2 - 0.42
Auxiliary boiler 1 1barg 0.19
Admin Mechanical room 1 1barg 0.05
Canteen Building 1 ‐ ‐
Total Gasoil Consumption for 1 Block CCPP 22.66
NG Fuel System
Gasoil Fuel System
1‐ Introduction
2‐Combined
Cycle Power
Plant
3‐ Fuel Oil
Treatment Plant
4‐Mapna Gas
Turbine
Technologies
5‐ Case study
6‐Result
7‐ Reco’s

8. Gas & Liquid Fuel Specification
Item Unit
Abadan
Refinery
Arak
Refinery
Esfahan
Refinery
Bandar
Abbas
Refinery
Tabriz
Refinery
Tehran
Refinery
Shiraz
Refinery
Kermanshah
Refinery
Density
@15° C
Kg/
m3
958.9 959 946.9 964.2 959.7 959.1 954.9 903.9
Flash point C 91 92 73 72 109 82 108 81
Kin viscosity
@50°C
cSt 274.4 270.6 230.7 285.2 210.5 198.8 161.1 29.4
Vis. Red
Wood
@37.8°C
C 2444 2406 2007 2552 1805 1688 1311 197
Pour Point Wt% 10 10 4.4 ‐1.1 15.6 10 21.1 23.9
Total sulfur Wt% 2.991 2.950 2.709 3.0 2.706 2.781 2.302 1.690
Carbon R. Wt% 9.7 10.4 9.68 12.3 8.9 9.4 5.41 4.2
Ash Wt% 0.057 0.03 0.027 0.047 0.035 0.047 0.034 0.008
Water &
sediment
Vol% Zero Zero 0.05 Zero Zero 0.04 0.05 Zero
Calorific
Value
Mj/k
g
42.78 42.8 43.06 42.64 42.87 42.83 43.21 44.13
Vanadium
content ppm 117 123* 190* 105 149 222* 321* 38*
8
Statistics for HFO Composition for 8 refineries / Iran
1‐ Introduction
2‐Combined
Cycle Power
Plant
3‐ Fuel Oil
Treatment Plant
4‐Mapna Gas
Turbine
Technologies
5‐ Case study
6‐Result
7‐ Reco’s

9. HFO consumption for each Gas Turbine is estimated around 1,000,000 lit per day.
Ni (ppm)V (ppm)Region
10 to 5050 to 500South America
10 to 10030 to 200California
5 to 1015 to 30Alaska
1 to 105 to 50Middle East
0 to 150 to 50North Africa
5 to 300 to 3S.E. Asia
Typical Vanadium and Nickel Contents
9
Typical Vanadium and Nickel Contents in Fuel Oil 1‐ Introduction
2‐Combined
Cycle Power
Plant
3‐ Fuel Oil
Treatment Plant
4‐Mapna Gas
Turbine
Technologies
5‐ Case study
6‐Result
7‐ Reco’s

10. GTLimitations
Substance Test Unit Natural Gas Gasoil Heavy Fuel Oil
Total Dust ASTM D 3605 ppm ≤ 20 ≤ 20 ≤ 20
Vanadium (V) ASTM D 3605 ppm ≤ 0.5 ≤ 0.5 ≤ 0.5
Lead (Pb) ASTM D 3605 ppm ≤ 1.0 ≤ 1.0 ≤ 1.0
Sodium + Potassium
(Na+K)
ASTM D 3605 ppm ≤ 0.5 ≤ 0.5 ≤ 0.5
Calcium (Ca) ASTM D 3605 ppm ≤ 10 ≤ 10 ≤ 10
Ash ASTM D 482 ppm ‐ ≤ 100 ≤ 100
Nitrogen (N) ASTM D 4629 ppm
locally applicable
emissions
guidelines
locally applicable
emissions
guidelines
locally applicable
emissions
guidelines
Sulfur (S) ASTM D 129 ppm ≤ 20 1‐4 % 1‐4%
Hydrogen sulfide (H2S)
ASTM D 1945 ppm ≤ 10 ‐ ‐
Mercaptans ASTM D 3227 ppm ≤ 10 ‐ ‐
Acetylene (C2H2) ASTM D 1945
Vol.
%
≤ 0.1 ‐ ‐
Hydrogen (H2) ASTM D 1945
Vol.
%
≤ 1 ‐ ‐
Ethane (C2H6) ASTM D 2887
Vol.
%
≤ 15 ‐ ‐
Higher molecular‐
weight hydrocarbons)
CnHm (n ≥2)
ASTM D 2887
Vol.
%
≤ 10 ‐ ‐
10
Limits for Chemical Contaminants
1‐ Introduction
2‐Combined
Cycle Power
Plant
3‐ Fuel Oil
Treatment Plant
4‐Mapna Gas
Turbine
Technologies
5‐ Case study
6‐Result
7‐ Reco’s

11. Main Process Parts
1.Raw water supply skid
2.Demulsifier supply skid
3.HFO Pre‐heater
4.HFO Heater
5.Mixers & Separators
6.Common waste treatment skid
7.Vanadium Inhibitor
8.Common treated HFO storage tank
9.Common treated HFO forwarding skid
11
1‐ Introduction
2‐Combined
Cycle Power
Plant
3‐ Fuel Oil
Treatment Plant
4‐Mapna Gas
Turbine
Technologies
5‐ Case study
6‐Result
7‐ Reco’s

12. Utility Consumption for One Block
(Capacity: 2*47 m3/hr)
Instrument
Air
Water
Balance
Steam &
Condensate
Balance
Max
Operability
Heat Duty
Electrical Power
Consumption
Item
Nm3/hrm3/hr
LPCLPS
KWKW
Kg/hrKg/hr
2261520015200143201300Total
12
Utility Consumption for FOTP ; capacity= 2*47 m3/hr
1‐ Introduction
2‐Combined
Cycle Power
Plant
3‐ Fuel Oil
Treatment Plant
4‐Mapna Gas
Turbine
Technologies
5‐ Case study
6‐Result
7‐ Reco’s

13. Reason for FOTP System
To minimize the risk of hot temp. corrosion
Increase the life time of the turbine blades
Reduce the content of sediments drastically
Reduction of lifecycle cost of the gas turbine
13
1‐ Introduction
2‐Combined
Cycle Power
Plant
3‐ Fuel Oil
Treatment Plant
4‐Mapna Gas
Turbine
Technologies
5‐ Case study
6‐Result
7‐ Reco’s

14. Simulation
14
1‐ Introduction
2‐Combined
Cycle Power
Plant
3‐ Fuel Oil
Treatment Plant
4‐Mapna Gas
Turbine
Technologies
5‐ Case study
6‐Result
7‐ Reco’s

15. HFO Treatment Unit‐ One Train
15
1‐ Introduction
2‐Combined
Cycle Power
Plant
3‐ Fuel Oil
Treatment Plant
4‐Mapna Gas
Turbine
Technologies
5‐ Case study
6‐Result
7‐ Reco’s

16. Feed Forwarding Heater Skid
16
1‐ Introduction
2‐Combined
Cycle Power
Plant
3‐ Fuel Oil
Treatment Plant
4‐Mapna Gas
Turbine
Technologies
5‐ Case study
6‐Result
7‐ Reco’s

17. Turbine Inlet Temp versus Vanadium
content
17
1‐ Introduction
2‐Combined
Cycle Power
Plant
3‐ Fuel Oil
Treatment Plant
4‐Mapna Gas
Turbine
Technologies
5‐ Case study
6‐Result
7‐ Reco’s

18. Standard Flame tube TIT= 910 °C
Special Flame tube for HFO TIT= 1010° C
Factor f for counting
operating hours
Contamination in the fuel in ppm
VanadiumNa+K
10.5≤0.5≤
1.50.5≤0.5 ≤ Na+K ≤ 1
1.50.5 ≤ Na+K ≤ 10.5≤
Short tip from Graph
18
1‐ Introduction
2‐Combined
Cycle Power
Plant
3‐ Fuel Oil
Treatment Plant
4‐Mapna Gas
Turbine
Technologies
5‐ Case study
6‐Result
7‐ Reco’s

19. EfficiencyNominal PowerTurbine TypeItem
38183 MWMAP2B1
34.6170 MWMAP2A2
34.5166 MWMAP2+3
34.42162 MWV94.2 (5)4
34.42157 MWV94.2 (3)5
3240 MWMG‐406
2720 MWMG‐207
Mapna Gas Turbines Technologies
19
Mapna Gas Turbine: Types, Nominal Power & Efficiency
1‐ Introduction
2‐Combined
Cycle Power
Plant
3‐ Fuel Oil
Treatment Plant
4‐Mapna Gas
Turbine
Technologies
5‐ Case study
6‐Result
7‐ Reco’s

20. Pilot Plant for Fuel Atomization
20
1‐ Introduction
2‐Combined
Cycle Power
Plant
3‐ Fuel Oil
Treatment Plant
4‐Mapna Gas
Turbine
Technologies
5‐ Case study
6‐Result
7‐ Reco’s

21. Case study:
Kermanshah Power Plant /Iran
implemented FOTP from Ambarli PP
21
1‐ Introduction
2‐Combined
Cycle Power
Plant
3‐ Fuel Oil
Treatment Plant
4‐Mapna Gas
Turbine
Technologies
5‐ Case study
6‐Result
7‐ Reco’s

22. General Description
22
Four (4) existing V94.2 GT
already operating with natural gas and gasoil
Two of them to operate with Heavy Fuel Oil
1‐ Introduction
2‐Combined
Cycle Power
Plant
3‐ Fuel Oil
Treatment Plant
4‐Mapna Gas
Turbine
Technologies
5‐ Case study
6‐Result
7‐ Reco’s

23. Scope of Work
1.Inspection of existing Gas turbines
2.Modification in BOP
3.Supply of first filling, Spares
4.Engineering and Design Services
5.Packing, Transportation, Offloading
6.Warehousing and preservation
7.Civil & Installation Work
8.Test and Commissioning
23
1‐ Introduction
2‐Combined
Cycle Power
Plant
3‐ Fuel Oil
Treatment Plant
4‐Mapna Gas
Turbine
Technologies
5‐ Case study
6‐Result
7‐ Reco’s

24. Problems in Executing plan
•Modification in Existing Gas Power Plant
•Shortage of Instrumentation in FOTP &
modification in the Control System of GT
•Reduction of Nominal Out Put Power
•Environmental Side Effects
•Increasing the maintenance
•Decreasing the Life time of main parts
24
1‐ Introduction
2‐Combined
Cycle Power
Plant
3‐ Fuel Oil
Treatment Plant
4‐Mapna Gas
Turbine
Technologies
5‐ Case study
6‐Result
7‐ Reco’s

25. HFO SYSTEM LEGEND
UBA: LV Switchgear Room
UBD: Auxiliary Transformer
UEJ: 2*1000 m3 Treated HFO Storage Tanks
UEL 01: HFO Untreated Forwarding Pump Station
UEL 02: HFO Treated Forwarding Pump Station
UEM01: HFO Treatment Station
UEM02: Area for HFO Forwarding Heater Skids
UHB: Auxiliary Boiler
UGC: Water Storage Tanks
UGD: Water Treatment Plant
UGE: Neutralization Pit
HFO SYSTEM LEGEND
UBA: LV Switchgear Room
UBD: Auxiliary Transformer
UEJ: 2*1000 m3 Treated HFO Storage Tanks
UEL 01: HFO Untreated Forwarding Pump Station
UEL 02: HFO Treated Forwarding Pump Station
UEM01: HFO Treatment Station
UEM02: Area for HFO Forwarding Heater Skids
UHB: Auxiliary Boiler
UGC: Water Storage Tanks
UGD: Water Treatment Plant
UGE: Neutralization Pit
General layout ‐FOTP Section
25
1‐ Introduction
2‐Combined
Cycle Power
Plant
3‐ Fuel Oil
Treatment Plant
4‐Mapna Gas
Turbine
Technologies
5‐ Case study
6‐Result
7‐ Reco’s

26. Item Parameter Unit Value
1
Ambient air temperature:
Design for performance
Maximum (absolute)
Minimum (absolute)
Annual mean of max. temperature
Annual mean of min. temperature
Design for HVAC systems
°C
15
42
‐21
23.9
7.2

2 Site Elevation: m 1300
3
Barometric pressure:
Design for performance
mbar 866
4
Humidity:
Design for performance
Maximum
Minimum
Design for HVAC systems:
%
60
83
15

5 Maximum wind velocity km/h 130
6 Ground Seismic horizontal Acceleration g 0.3
Site Conditions
26
Kermanshah Climatic Conditions
1‐ Introduction
2‐Combined
Cycle Power
Plant
3‐ Fuel Oil
Treatment Plant
4‐Mapna Gas
Turbine
Technologies
5‐ Case study
6‐Result
7‐ Reco’s

27. Item ION VALUE
1 PH 7.4‐7.5
2 Cond. 410‐450 (µs/Cm)
3 T.H. 120‐260 (mg/l)
4 Ca2+ 110 (mg/l)
5 Mg2+ 150 (mg/l)
6 Na+ 74 (mg/l)
7 TDS 206 (mg/l)
8 Turb. 0.6 (NTU)
Raw Water Analysis
27
Kermanshah Raw Water Analysis
1‐ Introduction
2‐Combined
Cycle Power
Plant
3‐ Fuel Oil
Treatment Plant
4‐Mapna Gas
Turbine
Technologies
5‐ Case study
6‐Result
7‐ Reco’s

28. Spec. Unit Value
Constituents
C Mass % n.a
O Mass % n.a
S Mass % 1.69
N Mass % n.a
H Mass % n.a
Contaminants
Water &sediment Vol % zero
Coke residues wt % 4.2
Ash ppm 80
Na+K ppm 50 (worth case)
V ppm 38
Pb ppm n.a
Ca ppm n.a
Properties
Lower heating value(LHV) MJ/Kg n.a
Higher heating value(HHV) MJ/Kg 44.13
Density at 15° c Kg/m3 903.9
Kinematic Vis. @ 50° C cSt 29.4
Flash point °C 81°C
Pour Point °C 23.9
Spec. Value Unit
C 74.869 wt%
H 25.131 wt%
LHV 50035 KJ/kg
Fuel Gas
Temperature
15 °C
Spec. Value Unit
C 86.4 wt%
H 13.4 wt%
S 0.2 wt%
O 0 wt%
N 0 wt%
LHV 42600 KJ/kg
Kermanshah Fuel Composition
28
UntreatedHFOComposition
Natural Gas Composition
Gas Oil Composition
1‐ Introduction
2‐Combined
Cycle Power
Plant
3‐ Fuel Oil
Treatment Plant
4‐Mapna Gas
Turbine
Technologies
5‐ Case study
6‐Result
7‐ Reco’s

29. Specification Unit Quantity
Water content+ sediment Vol % *
Coke residues wt % tbd
Ash ppm(wt) ≤100
Na+K ppm(wt) ≤0.5
V ppm(wt) ≤0.5
Pb ppm(wt) *
Ca ppm(wt) *
Fe ppm(wt) ‐
Ni ppm(wt) ‐
Estimated Composition for Treated HFO
29
Estimated Composition for Treated HFO
1‐ Introduction
2‐Combined
Cycle Power
Plant
3‐ Fuel Oil
Treatment Plant
4‐Mapna Gas
Turbine
Technologies
5‐ Case study
6‐Result
7‐ Reco’s

30. 1‐Required Modification in Mechanical Equipment
2‐Required Modification in Electrical Equipment
3‐Required Modification in I&C Equipment
Required modification in GT
30
1‐ Introduction
2‐Combined
Cycle Power
Plant
3‐ Fuel Oil
Treatment Plant
4‐Mapna Gas
Turbine
Technologies
5‐ Case study
6‐Result
7‐ Reco’s

31. Ambarli /Turkey Power Plant
Main Part
 6Gas Turbines(V94.2)
 3 Steam Turbines
FOTP
 Date of using HFO : 1994‐1996
 Technology: Alfa Laval Co.
 Capacity: Total 240 m3/hr (4*60 m3/hr)
TIT
Power
Output
Fuel
1050 °C139 MWN.G
1050 °C139 MWLFO
960 °C116 MWHFO
31
1‐ Introduction
2‐Combined
Cycle Power
Plant
3‐ Fuel Oil
Treatment Plant
4‐Mapna Gas
Turbine
Technologies
5‐ Case study
6‐Result
7‐ Reco’s

32. Ambarli /Turkey Power Plant
32
Gas Oil & Fuel Oil Skids in Gas Turbine Hall
1‐ Introduction
2‐Combined
Cycle Power
Plant
3‐ Fuel Oil
Treatment Plant
4‐Mapna Gas
Turbine
Technologies
5‐ Case study
6‐Result
7‐ Reco’s

33. TIT/OTC for HFO
(°C)
TIT/OTC for LFO
(°C)
TIT/OTC for NG
(°C)
‐1050/5251051/524Unit # 1
‐1050/5251048/523Unit # 2
9981064/5211050.1/526Unit # 3
9981055/5261053.4/527Unit # 4
TIT/OTC Parameters
Power Output
Water
injected flow
Auxiliary Power
Consumption
(KW)
Power Output (MW)Fuel
-870 KW121.6N.G
No‐Water Injection1730118.5HFO
35% of fuel flow rate1860122HFO
Result of Performance Data
33
1‐ Introduction
2‐Combined
Cycle Power
Plant
3‐ Fuel Oil
Treatment Plant
4‐Mapna Gas
Turbine
Technologies
5‐ Case study
6‐Result
7‐ Reco’s

34. 34
Recommendation
1‐ Introduction
2‐Combined
Cycle Power
Plant
3‐ Fuel Oil
Treatment Plant
4‐Mapna Gas
Turbine
Technologies
5‐ Case study
6‐Result
7‐ Reco’s
Economic Calculating (HFO/NG) is vital
Use the better coating to increase TIT
Apply automatic turbine Blades Washing
Integrate results in Process Sim (Aspen tech)
by Output power modelling (Thermo flow)

35. 35
Thanks for Attention………!!