Optimize gas turbine combustion with DLN 2.6+ technology
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I have explained the combustion and DLN2.6, dry low nox 2.6 + with better understanding. Trainings from Experts and my personal experience on gas turbines helps me understand the DLN 2.6 system. I hope trainee from Power Plants will like the slide. its good work of research for young trainees at Power Plants
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Optimize gas turbine combustion with DLN 2.6+ technology
- 1. DRY LOW NOX COMBUSTION SYSTEM DLN2.6+ GAS TURBINE 9HA Faisal Nadeem Lead Mechanical 1180 CCPP QATPL Power Plant
- 2. WHAT IS COMBUSTION A RAPID EXOTHERMIC PROCESS WHICH WILL DELIVER HIGH TEMPERATURE PRODUCTS THE ZONE WHICH SEPARATES THE REACTANTS AND THE PRODUCTS, AND WHERE THE TEMPERATURE RISE OCCURS WHAT IS FLAME
- 3. (Definitions) FLAMES PREMIXED FLAME (Blue) DIFFUSION FLAME (Yellow & Sooty) LAMINAR FLAME TURBULENT FLAME LAMINAR FLAME TURBULENT FLAME • SPARK IGNITION ENGINE • OXY-ACETYLENE WELDING TORCH • DRY LOW NOX (DLN 2.6) • CANDLE FLAME • GAS RANGE • DIESEL ENGINE • ALL FURNACES • CONVENTIONAL GAS TURBINE (Standard, MNQC) Flame Categorization
- 5. PREMIXED FLAME O2 O2 O2 O2 O 2 O 2 O 2 O 2 O 2 O 2 O2 O2 CH4 CH4 CH4 O 2 O 2 O 2 O2 O2 CH4 +O2 -> CH2 + OH + CO CH4 +O2 -> CH2 + OH + CO CH2 + O2 -> CO + OH Flame zone CO + O2 -> CO2 CO + O2 -> CO2 CO + O2 -> CO2 Premixed flow Post flame zone O 2
- 6. DIFFUSION VS. PREMIXED Diffusion Very Robust Stable Flame Typically Operable Over a 2000°F Temp. Rise Range High NOx Emissions Without Diluent Low CO Emissions Premixed > Very Narrow Operating Window > Typically Operable Over a 200-300°F Temp. Rise Range > Can Achieve Very Low NOx Emissions Without Diluent > Low CO Emissions Can Be Difficult
- 8. Transition Piece: Connects Individual Cylindrical Combustion Chambers to Annular Turbine Inlet Flowsleeve: Provides Flow Conditioning and Controlled Cooling to Liner Liner: Contains Reacting Flow Endcover: Contains Internal Passages to Route Fuel to Fuel Nozzles Fuel Nozzles: Inject Fuel to Reaction Zone ReactionZone: Fast Reactions Complete. NOx Produced In Rich Pockets Prior to Mixing Completion Post Reaction Zone: Fast Reactions Complete. NOx Produced In Rich Pockets Prior to Mixing Completion PCB Port: Instrumentation Port for Dynamics Acquisition Fuel Nozzle s FA DLN COMBUSTION SYSTEM
- 9. N-263 Liner Impingement Cooled Transition Piece Effusion Cooled Bluff Body Cap Assembly Steam Injection Manifold For Power Augmentation Cast, Fully Faired Fuel Nozzles Turbulated Backside Cooling Advanced Cooling on Liner Aft End Cloth Seals FA DLN COMBUSTION SYSTEM
- 10. DLN2+ Premixer Operation Swirler and fuel nozzle Combined – “Swozzle” Premixing Diffusion Fuel DLN2+ Premixer (9FA+e, 7/9FB, 9H, 6C, 52E) Swozzle approach to address flashback / flameholding Swirl Stabilized Premixed Flame F/A mixture recirculates back into Hot pilot flame for flame stability Diffusion Fuel Injection Anchors premixed flame in piloted Premixed mode Inlet Flow Conditioner - IFC Swirler Vanes Diffusion Fuel Tip Diffusion Fuel Premix Fuel Fuel Ports
- 11. DLN2.6+ COMBUSTION SYSTEM Product Capability 40% Turndown 9 ppm NOx 9 ppm CO Advance Thermal Barrier Coating Super B DLN 2.6 Like “5 around 1 Nozzle Arrangement EI Transition Piece Cooling and Sealing
- 12. 9HA REVERSE FLOW COMBUSTOR ARRANGEMENT
- 13. COMBUSTOR INSIDE VIEW AND PARTS
- 14. 9HA VIEW AND PARTS
- 15. DLN 2.6 DLN 2+ DLN 2.6+DLN 2+ DLN 2+ DLN 2.5 DLN 2.5 DLN 2.5 DLN 1 7FA+e / 7241 9FA+e / 9351 9FA+e 7FB / 7251 9FB / 9371 9H 6C 5-2E 7EA Number of Nozzles 6 5 6 4 5 5 5 5 7 Center Y/N Y N Y N N Y Y Y Y ISO Baseload T3.9 2664 2679 2664 2802 2794 2752 2680 2482 2176 T rise (deg F) 1910 1912 2011 1999 1878 1858 1680 1506 ISO Baseload TCD 754 766 766 791 795 873 821 802 670 NOx guarantee (ppmv@15%O2) 9 25 9* 25 25 25 15 15 9 Turndown range 40% 50% 40% 55% 50% 50% 40% 50% 70% Delta P (%) 5.7% 6.3% 6.0% 6.5% 6.5% 6.2% 7.1% 6.2% 4.5% Heat Release per can (BTU/sec) 31571 35385 36822 34146 38423 57206 18626 13533 24749 COMBUSTION SYSTEMS FOR LARGE GAS TURBINES 1898 * Introduced at 15 ppm
- 16. D5 GCV GCV3 GCV2 GCV1 Speed Ratio Valve Strainer Gas Manifold Gas Manifold Gas Manifold Gas Manifold Metering Tube Gas Fuel Scrubber Gas Company Combustion Can Gas Fuel Module Water Bath Heater Pressure Reducing Station Gas Compressor Coalescing Filter Start-up Heater Fuel Moisturization Performance Heater Filter Separator Knock-Out Drum Final Filtration Upstream of Gas Module Flow Indication to Mark VI Protection of valves and fuel nozzles Regulates Fuel Flow/Pressure . Isolates Fuel “Splits” Fuel between different nozzles. Equally distributes flow between combustion cans. Aux Stop Valve Knock-out Drum– Removes Liquid Slugs when Expected in Fuel Supply Filter Separator-Removes Particulate and Liquids from Inlet to Water Bath Heater or Gas Compressor (If provided). Water Bath Heater – Superheats Fuel to Prevent Formation of Liquids Across Pressure Reducing Valves Pressure Reducing Station – Reduces and Regulates the Gas Fuel Supply to Levels and Limits Required by the Gas Turbine. Gas Compressor – Increases gas fuel pressure when supply is less than that required by the Gas Turbine. Coalescing Filter – Removes liquids upstream of start-up heater to insure superheated fuel is liquid free. Start-up Heater – Increases/Maintains the fuels superheat level when fuel supply is below minimum required. Fuel Moisturization – Saturates the gas fuel to increase its moisture content/heating value. Performance Heater – To heat gas fuel to improve the heat rate and efficiency of the gas turbine cycle. Normally heated to 365F Applied on Heated Fuel Units Gas Fuel Module Gas Fuel Systems … Structure and Hardware D5 GCV GCV3 GCV2 GCV1 Speed Ratio Valve Strainer Gas Manifold Gas Manifold Gas Manifold Gas Manifold Metering Tube Gas Fuel Scrubber Gas Company Combustion Can Gas Fuel Module Water Bath Heater Pressure Reducing Station Gas Compressor Coalescing Filter Start-up Heater Fuel Moisturization Performance Heater Filter Separator Knock-Out Drum Final Filtration Upstream of Gas Module Flow Indication to Mark VI Protection of valves and fuel nozzles Regulates Fuel Flow/Pressure . Isolates Fuel “Splits” Fuel between different nozzles. Equally distributes flow between combustion cans. Aux Stop Valve Applied on Heated Fuel Units
- 17. FUEL CONDITIONING SKID Performance Heater – To heat gas fuel to improve the heat rate and efficiency of the gas turbine cycle. Normally heated to 365F Fuel Moisturization – Saturates the gas fuel to increase its moisture content/heating value. Start-up Heater – Increases/Maintains the fuels superheat level when fuel supply is below minimum required. Coalescing Filter – Removes liquids upstream of start-up heater to insure superheated fuel is liquid free. Knock-out Drum– Removes Liquid Slugs when Expected in Fuel Supply
- 18. DLN 2.6 Design Intent Higher Firing Temperature Machines ~ 7Fa, 9EC, G, H Evolution of DLN-2 ~ Goal of reaching 9ppm NOx Single Burning Zone, total premix combustor What are we trying to control?... and how... Unit load and fuel split via gas fuel staging ~ four independent gas fuel passages Techniques: Cascaded Flow & Load Control control valves positioned based upon flow characteristics & critical pressure drop across contol valves to achieve desired flow split & load control combustion reference temperature TTRF1 (model of T4) flow scheduling based upon TTRF1
- 19. pm3 pm2 pm3 pm2 pm3 pm1 q q q q q q q q q q q q PM2 (2 nozzles) located at crossfire tubes PM3 (3 nozzles) PM1 (1 nozzle) Q (15 pegs) DLN2.6 Fuel nozzle arrangement 6 Premix Burners - 5 radial burners (PM2 & PM3) are identical in design and effective area. The single center burner (PM1) is physically smaller, however the fuel nozzle effective area is identical to the outer five nozzles. Quaternary Pegs are located circumferentially around the forward combustion casing distributing fuel through eight holes per peg. q q q
- 20. DLN-2.6 GAS FUEL SYSTEM GCV3 GAS CONTROL PM3 SRV SPEED/RATIO VALVE GCV1 GAS CONTROL PM1 GCV2 GAS CONTROL PM2 GAS SKID SRV GCV4 GCV2 GCV1 GCV3 PM3 - 3 NOZ. PRE-MIX ONLY PM2 - 2 NOZ. PRE-MIX ONLY PM1 - 1 NOZ. PRE-MIX ONLY Q - QUAT MANIFOLD, CASING, PRE-MIX ONLY PM2 Q 6 BURNERS TURBINE COMPARTMENT BURNING SINGLE ZONE PM1 PM3 GCV4 GAS CONTROL Quaternary
- 21. DLN 2.6 Gas Fuel System PC FM PM 1 GAS MAN. PM 2 GAS MAN. PM 3 GAS MAN. QUAT GAS MAN. TRIP OIL CONTROL OIL CONTROL OIL MG2-1 96FF-1,-2,-3 FT-GI-1,-2,-3 VGC-1 VGC-2 VGC-3 VGC-4 VSR-1 TE TE TE TE FM FM FM FM Y-STRAINER RT-FG3 RT-FG2 RT-FG1 RT-FG4 65GC-1 VH5-2 65GC-2 VH5-3 65GC-3 VH5-4 65GC-4 VH5-5 TRIP OIL 90SR-1 VH5-1 96GC-1,-2 96GC-3,-4 96GC-5,-6 96GC-7,-8 96SR-1,-2 MG1-1 MG1-2 MG1-3 MG1-4 20VG-1 PT PT PT 96FG-2A 96FG-2B 96FG-2C MG4-4 96FG-5D 96FF-5D MG4-3 96FG-5C 96FF-5C MG4-2 96FG-5B 96FF-5B MG4-1 96FG-5A 96FF-5A PS 63FG-2,-3 PT 96FG-1 GAS PURGE OIL FUEL W/ STEAM INJECTION ONLY FH8-4 FH8-3 FH8-2 FH8-1 FH7-1 TUNING VALVE TUNING VALVE
- 23. SRV GCV1 GCV4 GCV2 GCV3 GCV4 - (Quat) 4.0” WOODWARD angle body control valve 0.750” stroke, linear trim, 300 lb flange GCV1 - (PM1) 4.0” WOODWARD angle body control valve 1.125” stroke, linear trim, 300 lb flange GCV2 - (PM2) 6.0” WOODWARD angle body control valve 1.125” stroke, linear trim, 300 lb flange GCV3 - (PM3) 8.0” WOODWARD angle body control valve 1.125” stroke, linear trim, 300 lb flange Gas Control Valves - ~Control unit load and flow split ~Independent 2-way fisher EAB design ~Hydraulically actuated, spring return closed ~3 coil servo controlled ~Redundant LVDT position feedback ~Trip Oil activated pilot required for actuation ~Class IV shutoff clasification per ANSI B16.104/FCI 70-2 e Proprietary Information john cole 1996 P2 pressure tap in non- turbulent flow field
- 24. Spark Plugs retracting unique to DLN 2.6 Flame Detection Standard UV detectors Four per unit not unique to DLN 2.6 CPD Measurement Triple redundant CPD transducers DLN-2.6 Hardware Flow Split Definition Total Flow = (PM3/(PM2+PM3))/(PM2/(PM2+PM3)) + PM1/(PM1+PM2+PM3) + Q/Total example base load fuel split: 60/40 +16.667 + 10 PM3 flow = 60 % of PM2+PM3 flow (45% of total flow) PM2 flow = 40% of PM2+PM3 scheduled flow (30% of total flow) PM1 flow = 16.667% of PM1+PM2+PM3 scheduled flow (15% of total flow) Q flow = 10% of total fuel flow
- 25. 9HA INTERFACE
- 26. PM1+PM2 PM1 DLN-2.6 TYPICAL LOADING SEQUENCE START PM1+PM3 PM1+PM2 PM2+PM3+Q PM1+PM2+PM3+Q (firing and initial crossfire) PM2+PM3 PM2 (Complete crossfire to 95 % speed) (95 % speed to TTRF1 switch #1) (TTRF1 switch #1 to #2) (TTRF1 switch #2 to #3) (TTRF1 switch #3, brief duration) (TTRF1 switch #3 + a time delay to #4) (Above TTRF1 switch #4 to base load)
- 27. DLN-2.6 GAS FUEL SYSTEM GAS SKID Q PM1 PM3 TURBINE COMPARTMENT PM1 + PM2 + PM3 + Q SRV GCV4 GCV2 GCV1 GCV3 PM2 Typical Base load operation for the DLN2.6 Combustion System e Proprietary Information john cole 1996
- 28. DLN OPERABILITY NOx NOx Guarantee Window CO CO Guarantee Fuel-Air Ratio Dynamics Dynamics Limit NOx CO Dynamics Operability Window Lean Blow Out Window Window Tfire (Power) Lean Blow Out Window Dynamics Fuel-Air Ratio Fuel-Air Ratio Fuel-Air Ratio
- 29. BREAKER OPEN EVENT UNIT FLAME-OUT DLN-2.6 TYPICAL UN-LOADING SEQUENCE STOP PM1+PM3 PM1+PM2 PM2+PM3+Q PM1+PM2+PM3+Q PM1 PM1+PM2 (FSNL operating mode)
- 30. DLN-2.6 Operational Specifics all values are specific MS7FA at PSC, Ft. St. Vrain Loading times : Normal loading : Start Command to FSNL : 11:18 min Start Command to Base load : 24:26 min Fast loading : Start Command to FSNL : 06:29 min Start Command to Base load : 10:53 min Load transients during mode transitions : Maximum loading transient : +-2.99 % rated load Optimal Base Load Emissions : 8 ppm NOx 7 ppm CO @15% O2 0 ppm unburned hydrocarbons Dynamics : 1/2 psi pp
- 31. NOX AT 15% O2 VS. PERCENT LOAD 7FA DLN 2.6 Emissions vs. GT Load 0 10 20 30 40 50 60 70 80 0 10 20 30 40 50 60 70 80 90 100 % Gas Turbine Load IS O N Ox @ 15% ppmvd Mode 1 Mode 3 Mode 4 Mode 6
- 32. GT Operation with DLN (IGV Temperature Control) Overall F/A Load - MW Traditional Simple-Cycle (Constant Air Flow) Airflow Fuel Overall F/A Load - MW Load - MW Load - MW Traditional Combined Cycle • Inlet Guide Vanes throttle Air into Compressor • IGV start opening at ~50% load • Fuel Flow increases w/ Load • F/A Maintained 50-100% Load • Combustor operates just above LBO condition • Ideal for Low NOx 50-100% Load when operated with inlet bleed heat (IBH) DLN Equipped Turbines in Simple Cycle Applications Typically Operate with IGV Temperature Control for Better Turndown IGV Temperature Control
- 34. ZONAL METHOD OF INTRODUCING AIR
- 35. FLAME STABILITY
- 36. STABILITY LOOP
- 40. STABILITY LOOP
- 42. COMMENT AND ASK ANYTHING