Technical Presentation on - MANFREDDA & · PDF file• Technical presentation ... –...
Transcript of Technical Presentation on - MANFREDDA & · PDF file• Technical presentation ... –...
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Technical
Presentation on
Exhaust Systems
Acoustical Components
Dampers & EJ’s
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Presentation
• Introduction
• Capability overview
• Company profile
• Reference projects
• Technical presentation
• Case study on Retrofits
• General discussion
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Aarding Thermal Acoustics
Introduction & Capabilities
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• Well established company (started in 1960)
• Offices in Netherlands, Singapore, USA, Canada, Brazil, China, India
• Active in the Power-Energy and Petrochemical market
• Part of CECO Environmental Group (Traded on NASDAQ, CECE, Annual Sales ~$250M)
• Strong global presence
• $50M annual sales worldwide
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• Supply of custom designed turnkey systems
– Baseload systems
– Start Stop systems
• Service and Maintenance for existing Power Plants
– Both on mature as well as on advanced Advanced type systems
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Capabilities
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Strong Global Presence
• World-wide installed references • lobal fabrication experience • Multi-language staff (over 9 languages)
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Some General References – New Systems
– F9FA Bypass Stack GE-SADESSA
– F9F-05 Teststand Mobile Exhaust GE-Greenville
– F7FA PP13 PP14 12 Bypass Diverter Systems SCECO SAUDI
– TVA Paradise USA
– Shaybah M-East
– Los Guindos Latin America
– Energia Del Valle Latin America
– BLNG II Asia
– Jazan M-East
– Nuevo Pemex 3rd Train Latin America
– Shuqaiq M-East
– Bandirma II Asia
– Syncrude USA
– San Gabriel Latin America
– Wildcat USA
Over 300 BYPASS Diverter systems installed (small to the largest)
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General References - Retrofits
– Retrofits of ducts and section repairs BLNG BRUNEI
– F9E Corby UK Plenum,ducts and silencers EON ESBI UK
– F9E Inlet Duct upgrades & revamps AES Europe
– Retrofit of Exhaust system Silencer duct section PCS Singapore
– F9E Retrofit of Exhaust section including Diverter TNB Gelugor
– Retrofit of Exhaust Plenum System SESB Labuan
– Retrofit of Exhaust Duct & Plenum Section SUEZ Rayong
– Retrofit of GT Testcel KLMAIRFRANCE KLM Schiphol
– Retrofit of refinery based Exhaust LM2500 BP Lingen
– Retrofit of Complete Exhaust System CEB Mauritius
– Retrofit of Exhaust Plenum System Tampere Finland
– Retrofit of Exhaust Plenum System Shell Moerdijk
– Retrofit of Exhaust & Silencer System PTT Ratchaburi
– V94.2 Retrofit of Exhaust & Silencer System POWERTEK Bangladesh
– Large number of Vent silencers mainly US, EU and Asia
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In-House Engineering Capabilities
– Experienced engineers
• Industry related expertise
• Full range of reference projects
– Advanced Engineering Techniques
• Thermal Analysis
• CFD analysis
• Acoustic modelling
• Metallurgical testing
• HI CAD 3D design
Focus on Exhaust & Acoustical
systems
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• In House Design & Engineering
– All systems designed to order
• Worldwide Manufacturing
– Production facilities in Europe, North America, Middle East & Asia
• Site / installation supervision
Project driven
Engineering Solutions
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- EPC contractors,
- OEM: Turbine & HRSG suppliers
- Maintenance companies
- End Users
World-Wide supplier to
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World-Wide supplier to EPC contractors, turbine & HRSG suppliers and Engineering companies.
Ref. i.e.:
• GE
• Alstom
• Siemens / Westinghouse
• Nooter Erikson
• Shell-BLNG
• Suez-Glow Energy
• NEM
• CMI
• MHI
• Doosan
• Thosiba
• Deltak
• Cerrey
• Metka
• Vogt
• Marubeni
• Toyo /IKPT
• Sedae
• BP
• PTT Thai
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Gas Turbine
Exhaust Systems
Gas Turbine Combined Cycle System Gas Turbine Simple Cycle System
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Capabilities
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Capabilities include;
• Diverter Dampers (Toggle, Pivot, Louver)
• Guillotine Dampers/Blanking Plates
• Stack Dampers / Louver Dampers
• Turbine and Exhaust Expansion Joints
• Installation and commissioning supervision
• Turnkey projects including erection
• Service, maintenance and retrofit for existing power plants
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Capabilities
Bypass Stack – Simple Cycle
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Capabilities
Bypass Stack – Combined Cycle
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Capabilities
Bypass Stack – Combined Cycle
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Capabilities
Bypass Stack – Combined Cycle
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Capabilities
Bypass Retrofit in Malaysia
Plenum, Ducting & Diverter System
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Internally Insulated Ductwork
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Capabilities
Internal Insulation
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Capabilities (COLD CASING)
Internal Insulation System
The Internal insulation system consisting of:
- Outer casing of carbon steel (stiffenned)
- Sheeting + flat washers AISI 409/321 materials
- Studs + Nuts AISI 409/321,
- Bio Soluble insulation wool 64/128 kg/m3 in 50 mm layers,
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Capabilities – Inlet Ducts
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Capabilities – HRSG
Insulation Systems
• Top and Bottom Sections
• Sidewall Sections
Internals
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Large Diameter Stack Dampers
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Large turbine expansion joints
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Capabilities
Flue Gas Silencers
• Noise reduction after a gas turbine.
• Installed in Stacks or ductwork
• Proven Acoustical Design – EU Patented
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Capabilities
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Capabilities
Fluegas Silencers
European Patented Design
Silencer Assemblies
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Flue Gas Silencers
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Flue Gas Silencers
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Capabilities
Flue Gas Silencers / Baffles
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• Noise reduction in steam and gas
applications
• Proven Acoustical Design
• Compact Design
– Reduced weight
– Limited installation space required
Capabilities
Vent Silencers
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Capabilities
Vent Silencers
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Vent Silencers
• General
• Silencer type
• Diffusers
• Connections
• Additional Features
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Vent Silencers – Silencer type Inline Silencers Vent Silencers
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Vent Silencers - General
Design acc.:
• ASME B31.1/3
• PED (European projects, if
required)
Production Vent
Silencers in: – Malaysia
– The Netherlands
– Romania
– Russia
– USA
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Commissioning Silencers
• Noise reduction during a commissioning /
steam blow-down type application
• Designed for a rugged type service
• Inlet components designed to withstand
pressure loading, debris impact and free
water impact.
• Rental Silencer
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Commissioning Silencers
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Commissioning Silencers
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Gas Turbine Exhaust Systems
Ageing & Upgrades
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Ageing
Operational Damages
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Gas Turbine Exhaust Ducts
Major Drivers of Operational Damages
• Ageing
– Wear & Tear of Exhaust & Silencer Systems
– Multiple repair area’s weakening the Exhaust Structure
– Alloy Degradation
• Safety requirements
– Ageing systems showing excessive temperatures
– unplanned maintenance events (casing cracks/ruptures etc)
• Change in Power Plant Operation
– Market Driven two-shifting / Start Stops increase
– Higher Temperatures & flue gas velocities in the GT exhaust ducting.
– Minor defects in the external / internal insulation of exhaust ducts system rapidly leading to widespread damage (potential for significant loss of plant availability).
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Operational damages
GE Gas Turbine Exhaust Plenum
Severe damage to the casing.
Hot spots
Un-reliable and
Un-Safe operation
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Consequential
Damages as a result
of elevated
temperatures on
Bellows and transition
/ silencer ducts
Operational damages
GE Gas Turbine Ducts & Bellows
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Deferred maintenance
resulting in severe
exhaust system
damages as well as GT
damage
Operational damages
GE Gas Turbine Units
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Fire hazards as a
result of overheated
turbine compartments
Operational damages
GE Gas Turbine GT plenum duct GT side
and Flex plate system
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Severe
damage to
the
sheeting
and
insulation.
Operational damages
GE Gas Turbine Ducts – Insulation system
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Thermal Shock Severe cracking and degradation of original duct sections
Operational damages
GE Gas Turbine Ducts
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Repair by welding
Or
Section replacement
Does not offer a
Lasting solution
On Ageing and
older design Type
Exhaust Systems
Operational damages
GE Gas Turbine Ducts – Patch repairs
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Silencer Support failures
Sections damaged
Operational damages
GE Gas Turbine Ducts Flue Gas Silencers
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Upgrades & Life Extension
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• Reduction of annual costs – Lower annual maintenance costs
– Increased Unit availability
• Thermal improvement – Different options to reduce temperature levels and required
ventilation
• Safety – Lower (duct surface/bellow) temperatures
– Lower Load chamber temperatures / better accesability
Upgrades ; Objectives
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• Definition of system Requirements, Inspection & Analysis
• Upgrade of silencer systems
– Supporting Cyclic Power Plant Operation or Life extension
– Elimination of thermal shock for the silencer supports
• Upgrade of ducting systems
– utilising only internal insulation ( current status “cold casing design” )
– Improved alloy structures adapted to higher EGT & gasflow
– long term internal insulation integrity
– safer operating regime
– significantly reduced maintenance down time.
• Upgrade of transition areas such as bellow systems
– Temperature reductions in critical access area’s (E.G. Load Chamber)
Upgrades to current industry standards
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Thermographic periodical inspections
Upgrades : Monitoring & Inspections
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Examples of Analysis & Flow Modelling
Flow Modeling
Stress Calculations
Silencer Support
Stress Calculation Casing
Stress Calculations
Fluegas Silencers
Upgrades: Defining Solutions
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Example of dedicated silencer support design
Upgrades : Defining Solutions
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Example of upgraded Duct Design
Upgrades : Defining Solutions
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Example of ATA upgraded flex plate insulation kit FIK HTXA ™ temperature reduction at Plenum Duct Flex Plates
Bellow design installed
Upgrades : Defining Solutions
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GE type
Retrofit of
Exhaust Duct, Silencer assembly &
Plenum Duct
Case Study in Photographs
Report from a Recent Project
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Retrofit
Plenum Duct – Existing
Degraded
Flanges
Plenum Duct
Degraded &
Distorted Old
Design Plenum
Duct
Old design
Box Type
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Retrofit
Plenum Duct – Manufacturing
Half Moon
Sections
COLD Upgraded
Design Duct
Sectional Design to
accommodate fast
installation during
Overhaul
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Retrofit
Plenum Duct – Manufacturing
Half Moon
Sections
COLD Upgraded
Design Duct
Sectional Design to accommodate fast installation during Overhaul
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Retrofit
Plenum Duct – New
Inner (GT) Side
COLD Upgraded
Design Duct
Installation
Outer (GT) Side
COLD Upgraded
Design Duct
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Retrofit
Silencer Duct – New
Silencer duct
Including
support
structure
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Retrofit
Silencer Duct – New
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Retrofit of Exhaust Duct, Silencer
assembly & Plenum Duct
Exhaust Duct, Silencer Assy & Plenum Duct
Custom Designed based upon
• GT Gasflow & EGT
• Duct Surface Temperature Requirements
• Noise Abatement Requirements
• Actual Plant Layout
• Overhaul time & planning
• Expected Exhaust System Life Extension
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Retrofit
Exhaust Duct : Existing
Bulging duct casing
Degraded and
damaged Carbon
Steel Inner Duct
Leaking Bellows
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Retrofit
Exhaust Duct : Section Manufacturing
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Retrofit
Exhaust Duct : New
Custom
Designed
Access
Door
COLD Upgraded
Design Duct New
Bellow
System
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Retrofit
Silencer System - Existing
Detached
Silencer units
Damaged
Supports
Damaged
perforated
sheets &
depleted
Insulation
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Retrofit
Silencer System – Final Inspection
Patented Design
accommodating Cold
Casing structure
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Retrofit
Silencer System - New
Silencer Assembly installed in
Upgraded Cold Design Duct Upgraded Design
Supports
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If you need support for the
upgrade of your Exhaust
System please contact us at;
www.aarding.com