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1、CALPINEFuel Variability and Dry Low NOx Gas TurbinesMaritimes & Northeast Pipeline Technical Conference July 15th, 2008Peter So Calpine Turbine Maintenance GroupCalpine Corporation1CALPINE7/16/2008Peter Sos Background?BS of Mechanical Engineering?State of California Professional Engineer, Mechanical
2、 Engineering?14 years of industry experience?Ex-GE Field Engineer, startup engineer, Dry Low NOx tuner?Involved with early DLN 2.0 / DLN 2.6 startup activities?Manage a group responsible for controls and tuning support of Calpines GE 7FA fleet, total group experience just short of 50 years?Steering
3、committee member of GE 7F Users Group and past co-chairpersonCalpine Corporation2CALPINE7/16/2008Topics for Discussion?Calpine Overview?DLN Compare to Conventional NOx?DLN Systems Key Issues?DLN Systems Combustion Tuning Basics?GE DLN System at Westbrook?Calpines Experience?GE Wide Wobbe System Many
4、 Unanswered Questions?Summary?List of IssuesCalpine Corporation3CALPINE7/16/2008Calpine Overview?Calpine is the largest natural gas consumer in the United States and has substantial experience with operating F/G DLN technology gas turbines?82 power plants - 24,000 MWs?91 F/G technology gas turbines
5、with DLN combustion systems:?47 GE 7FAs 1,319,772 operating hours?40 Siemens 501Fs 1,543,789 operating hours?4 Siemens 501Gs 103,289 operating hoursCalpine Corporation4CALPINE7/16/2008Calpine Overview TMG?Calpine Turbine Maintenance Group formed in 1992?Self perform Combustion Inspections, Hot Gas P
6、ath, Majors amongst other maintenance activities?Staff of close to 60 and growing?Self perform combustion tuning activities since early 2000Calpine Corporation5CALPINE7/16/2008DLN Compare to Conventional NOx?Dry Low NOx - lower exhaust NOx levels (as low as 5 ppm vs 25 ppm)?Benefits of DLN:?Lower em
7、issions?Less maintenance effect on combustion and hot gas path parts?Lower operating cost of water/steam?Challenges of DLN:?System more sensitive to variables (i.e. fuel quality, ambient temperature)?Narrower operating range due to emissions limitations?System more complex, experienced O&M staff req
8、uired - Troubleshooting is difficultCalpine Corporation6CALPINE7/16/2008DLN Systems Key Issues?Importance of Fuel Specifications:?Gas turbine design based on historical fuel quality?OEM specifies limits to range of operation?Outside of these specifications - reduced reliability and parts damage?Wobb
9、e Index (WI) range?One of several interrelated gas quality parameters?Even within OEM range - limited adjustability to changes?Outside of historical fuel range fuel impacts unknown and may require equipment changes?Outside of OEM/historical range additional cost, downtime WILL occur?Rate of change:?
10、As important as WI range?Historically not much variation in gas quality - rate of change has not been a concern?Gas turbines designed in anticipation of a limited rate of change?Siemens has always specified rate of change criteria?GE not initially, but does now with Wide Wobbe OpFlex systemCalpine C
11、orporation7CALPINE7/16/2008DLN Systems Combustion Tuning Basics?Four criteria:?Combustion dynamics?Emissions permit requirements?Lean blow out stability concerns?Performance Depending on circumstance need to optimize for MWs, BTUs and/or turndown?Tuning for fuel quality:?Need to experience actual ga
12、s quality to properly tune?Tuning in anticipation of gas is “hit or miss”Calpine Corporation8CALPINE7/16/2008GE DLN System at Westbrook?Westbrook Energy Center 537 MW power plant located just outside of Portland, ME?Interconnected with M&N Joint Facilities?2 GE 7FA+e Gas Turbines with DLN 2.6 system
13、 - designed for 9 ppm NOx?Stack NOx permit with SCR is 2.5 ppm?DLN 2.6 fuel system includes 5 control valves, 14 combustion cans, 64 individual fuel nozzles, hundreds of individual injection pointsCalpine Corporation9CALPINE7/16/2008GE DLN System at Westbrook (cont.)Diagrams/Pictures Courtesy of GE
14、- GER-3568GCalpine Corporation10CALPINE7/16/2008GE DLN System at Westbrook (cont.)Diagrams/Pictures Courtesy of GE - GER-3568GCalpine Corporation11CALPINE7/16/2008GE DLN System at Westbrook (cont.)?DLN 2.6 System is highly sensitive?Great precision and fine tuning required at all times?Determining t
15、he exact adjustment needed takes substantial amounts of time and requires information on multiple variables (i.e. fuel quality, ambient temperature)?Typical tune adjusts schedule by 0.5-3% which equates to 0.005 to 0.034 inches change in actual PM3 valve movement as an exampleCalpine Corporation12CA
16、LPINE7/16/2008GE DLN System at Westbrook (cont.)?Tuning at Westbrook and most Calpine sites?Remote tuning capable with onsite personnel - provides quicker reaction to combustion issues?Continuous Dynamics Monitoring System (CDMS) monitors and records combustion dynamics?In-house tuning expertise?Computer infrastructure?Reflects a substantial capital investment at Westbrook and across CalpineCalpine Corporation13CALPINE7/16/
