ABB - Field Experience of Turbocharger Retrofit

© ABB Group / ABB TurbochargingStandard E October 18, 2011

Field experience of turbocharger retrofits to fulfill emission regulations on reciprocating gas compression engines

Mirko Lepel, ABB Turbo Systems Ltd / GMC Nashville, 3rd Oct 2011

© ABB Group / ABB TurbochargingOctober 18, 2011 | Slide 2 | Standard E

Turbocharger retrofits Why retrofit gas compression engines?

Why would a gas compression engine operator retrofit an engine?

Retrofits can be a cost-effective alternative to complete gas compression plant retirement/replacement e.g. if:

Engine required to fulfill future emission limits.

Engine is expected to continue operating for a few more years.

Spare part availability of the old turbocharger is poor and expensive, or custom engineering is needed.

Excessive downtime due to breakdowns of the old turbocharger.

Excessive fuel consumption due to low efficiency of the old turbocharger having significant impact on operating costs.

Technical support for old or discontinued turbocharger is unavailable.

Improvement of field serviceability by turbocharger OEM and/or local maintenance crews. This minimizes downtime and repair costs.


Turbocharger retrofits Retrofit process

Engine data

Customer requirements

Site / operating conditions

Definition of air specification

Definition of turbocharger frame size and initial specification

Optimizing turbo specification according to engine tests

Validation of final turbocharger specification to customer requirements

Selecting turbocharger from standard portfolio

Performance evaluation

Engine model validation

Performance optimization by simulation

Changing e.g. nozzle rings, diffusers and rotor components if required


Turbocharger retrofits Evaluation of data and performance optimization

Topology of engine model

Validated simulation tool with access to turbocharger database


Turbocharger retrofits Determination of frame size

Impact of mean effective pressure (bmep) for two different engines with identical power ratings on turbocharger frame size

impact on turbo cost - $/KW

V298

Csmaller frame size

larger frame size

high bmepengine

low bmepengine

V298

Csmaller frame size

larger frame size

high bmepengine

low bmepengine


*sV

0. 5 1.0 1.5 2. 0 2.5 3.0 3.5 4.01.0

1.5

2.0

2.5

3.0

3.5

4.0

4.5

5.0

5.5

6.0

. V2 98 [m3/s]

v to t/to t

* sV*sV*sV

0. 5 1.0 1.5 2. 0 2.5 3.0 3.5 4.01.0

1.5

2.0

2.5

3.0

3.5

4.0

4.5

5.0

5.5

6.0

v to t/to t

0. 5 1.0 1.5 2. 0 2.5 3.0 3.5 4.01.0

1.5

2.0

2.5

3.0

3.5

4.0

4.5

5.0

5.5

6.0

v to t/to t

0. 5 1.0 1.5 2. 0 2.5 3.0 3.5 4.01.0

1.5

2.0

2.5

3.0

3.5

4.0

4.5

5.0

5.5

6.0

v to t/to t

nTC

0. 5 1.0 1.5 2. 0 2.5 3.0 3.5 4.01.0

1.5

2.0

2.5

3.0

3.5

4.0

4.5

5.0

5.5

6.0

v to t/to t

. V298 [m3/s]

sV

C

0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.01.0

1.5

2.0

2.5

3.0

3.5

4.0

4.5

5.0

5.5

6.0

. V298 [m3/s]

vtot/tot

*sV*

sV*sV

sV

V298 [m3/s]

nTC

C

Turbocharger retrofits Optimization of TC specification / modular TC design

Impact on changing compressor trim

Impact on changing diffuser


Turbocharger retrofits Clark HSRA-8 engine with VTR304 – field experience

ABB VTR304-32 turbocharger

with external, anti-friction bearings ideal when engine oil is not

easily supplied to the turbo

Jet Assist is available on request to improve the rotor’s acceleration and subsequently the load acceptance of the engine

San Diego Gas and Electric (SDG&E) compressor station



Scavenging piston to assist gas exchange and stabilize the combustion

Topology of Clark HSRA-8

exhaust waste gateambient

compcomp

turbturb

Air receiver

Exhaust receiver

ambient

scavengingpiston

airjet assist

gas



Measurement results by AETC Benefits of the retrofit

Emissions reduced below requirements

Fuel consumption slightly reduced

Spare parts availability guaranteed

Capital cost avoidance (retiring and replacing compressor plant)

BSFC vs. B.S.NOxMoreno Valley Units #1 and #3

Pre and Post Conversion Test Full Load

8'000

8'500

9'000

9'500

10'000

10'500

0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0

B.S. NOx (g/BHP -HR)

BSF

C (B

TU/B

HP-H

R)

Unit 1 Pre-Conversion CB13 Cooper TC

Unit 3 Post-Conversion ABB VTR304-32Oct 28, 2010


Turbocharger retrofits Cooper-Bessemer 12Q145HC with TPL-73 - field experience

PG&E Los Medanos injection plant

Simulation and TC layout

Benefits of the retrofit

Fulfillment of emission compliance

Reduced fuel consumption


Capital cost avoidance (retiring and replacing compressor plant)

Full load availability of engine at high ambient temperatures (no derating)


Effective project planning

Engine knowledge (understanding of operational effects of modifications)

Accurate air specification for turbocharger

Predictive tools for emissions reduction, air consumption, etc.

Accurate measurements for baseline engine and subsequent testing

Turbocharger retrofits Requirements for a successful retrofit project


Emission reduction at or below requirements

Fuel efficiency improvements


Improved turbocharger reliability

Minimization of downtime

Full load availability at increased ambient temperatures (no derating)

Capital expenditure avoidance

Turbocharger retrofits Benefits of a successful retrofit project

© ABB Group / ABB TurbochargingStandard E October 18, 2011

Thank you for your attention!

For further information please visit us at our booth 100/102

ABB - Field Experience of Turbocharger Retrofit

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