Peter Brighton, Donaldson Australasia: CASE STUDY: Valley Power upgrade of Air Inlet Filter House and defective cooling

DONALDSON AUSTRALASIA PTY LTD

Valley Power Upgrade – Air Inlet Filter House and Defective Cooling with Peter Brighton

14th Annual Gas Turbine Systems Conference – Hilton Hotel Brisbane 30th October, 2013

INTRODUCTION

• Replace the air inlets and defective fog cooling system of

an existing 300 MW gas turbine plant at Valley Power Vic

• Review the logistics behind the design, manufacture,

quality, delivery and site supervision of the filter houses,

evaporative coolers with structures for 12 Pratt and

Whitney 25 MW gas turbines

• Review the increased summer capacity from evaporative

coolers and the benefits in meeting the guaranteed

performance

Source: www.gsabusiness.com, “GE develops new gas turbine in Greenville” Oct. 30, 2009

Site Issues

• Non OEM fogging system

• Blade corrosion/erosion concerns “ineffective fogging”

• Engine output (Warmer weather conditions)

Source: www.gsabusiness.com, “GE develops new gas turbine in Greenville” Oct. 30, 2009

“A” Station Filter Houses x 6

• Static Filter House

“A” Station Filter Houses x 6

• Static Filter system – 2 stages

- Pocket pre-filter

- Static panel filter

- Fogging “Downstream”

“B” Station Filter Houses x 6

• Static Filter House

• Condition of the Inlet silencer

downstream the filter house.

DOWNSTREAM ISSUES

CUSTOMER REQUIREMENTS

• Expectations

o Guaranteed

pressure drop

o Guaranteed

cooling efficiency

o Deliver and

Commission on

time

Improve Power

Plant Capacity

CUSTOMER REQUIREMENTS

• Design, manufacture,

supply, commission and

performance test.

o 6 x A Station Static

Filter Houses with

support structure

o 6 x B Station Static

Filter Houses with

support structure

o 12 x Evaporative

coolers

o 12 x Transition ducts

o 12 x Stairs and

access platforms

CUSTOMER REQUIREMENTS

• Considerations

o 2 separate

designs

o Existing site

services

o Engine removal

beam to support

structure for B

Station units.

CUSTOMER REQUIREMENTS

• Guarantees

o Cooling

efficiency - 88%

o Pressure Drop

1.5” w.g.

o Delivery 4 x “A”

Station and 2 x

“B” Station Sept

2009

o Delivery 2 x “A”

Station and 4 x

“B” Station March

2010

The Program

Main Task Sub Task Due Date Who

Sign Contract Day 0 Customer

Site Survey 17-03-2009 to 24-03-2009 DAPL

Equipment Design Preliminary GA Station A&B 6/04/2009 DAPL Preliminary P&I D 6/04/2009

Review +5 days after submission by Don. Customer/OE

HAZOP Study Participate 23-03-2009 Customer/DAPL/OE3

Report 27/03/2009 OE

Installation Manual High Level Preliminary 01-04-2009 DAPL

Equipment Design Final GA Station A&B +7 days after review of preliminary

by customer

DAPL

Review and accept +5 days after submission by Don. Customer/OE Foundation and loadings 18/05/2009 DAPL

Control Box Diagram 1/06/2009 DAPL

Quality QCIP/ITP 20/04/2009 DAPL

Review and accept +5 days after submission by Don. Customer/OE

Installation Manual Final 15/07/2009 DAPL

Review +5 days Customer/OE

O&M Manual Preliminary 29/06/2009 DAPL

Review +5 days Customer/OE

Final 11-11-2009 DAPL

Review +5 days Customer/OE

Delivery5

Program U5 Filter Houses (2-off) 1/09/2009 DAPL

U1 Filter Houses (2-off) 1/10/2009 DAPL

U2 Filter Houses (2-off) 1/10/2009 DAPL

U3 Filter Houses (2-off) 1/03/2010 DAPL

U6 Filter Houses (2-off) 1/03/2010 DAPL

U4 Filter Houses (2-off) 1/03/2010 DAPL

Commissioning and Testing U5 Filter Houses (2-off) not later than 27/10/2009 DAPL

U1 Filter Houses (2-off) not later than 26/11/2009 DAPL

U2 Filter Houses (2-off) not later than 26/11/2009 DAPL

U3 Filter Houses (2-off) not later than 26/04/2010 DAPL

U6 Filter Houses (2-off) not later than 26/04/2010 DAPL

U4 Filter Houses (2-off) not later than 26/04/2010 DAPL

Design

• Donaldson Europe Belgium.

o Complete design of the filterhouse and evaporative cooler system

Position of Manufacture

• Donaldson China Shekou

o GDS Filter House

o Evaporative Cooler structure and sump

o Hoppers

Donaldson China Chengdu

o Transition Ducts

o Support Structure

o Access Stairway and Platforms

Position of Manufacture

• Europe (Belgium)

o Control Panel

o Flow gages, sensors, ball valves,

EVAP plumbing

o Electricals, lighting etc, cable trays

o Junction Box

o Pump

o Bellows TD – Inlet.

o EVAP Distribution Panels

Position of Manufacture

• Australia (Wyong NSW)

o Filter Elements

QUALITY INSPECTION

• POM Inspections by Customer – Shekou and

Chengdu

o Material specifications and certificates ITP

o Dimensional Measurements

o Welding

o Paint

o Packing

o Contract

Ensure fit per designed tolerances keeping

any rectification work to a minimum

PRE “TRIAL” ASSEMBLY

• Shekou China

o GDS Filterhouse

o EVAP Section

o EVAP Sump

• Chengdu China

o Transition Duct

o Support Structure

DDP FREIGHT TO SITE

• All China freight consolidated in Shekou

o 72 x Open Top 40ft containers

o 36 x 40ft GP

• Belgium Critical components

o 6 x 40ft GP

Total 72 Open Top and 42 Gp’s delivered by side

loaders to site. Additionally 6 x 40ft GP’s from

DAPL for the filter elements and Evap media

Pads

DEMOLITION AND CIVILS

• Removal of old equipment was

contracted to others

• All Civil works were carried out by the

customer prior to installation of the

support structure

DELIVERED

• Components delivered at laydown area

near Valley Power.

• Some pre assy was required at the

location

INSTALLATION

Support Structure

• The support structure was erected prior to

removing the old units

• Stair and platform access was then lifted

in place allowing for service areas during

lifting of the modules

INSTALLATION

Support Beam

• Note the Beam on the

support structure for

the “B” Station units -

this allowed for the

removal of the engine

utilizing the Donaldson

support structure.

• All load ratings

calculated by

Donaldson Europe to

accommodate

additional weight to

remove the GT.

INSTALLATION

Module Assemblies

Each section was lifted separately

• Sump

• 3 x Evap Sections lifted separately on to

the sump

• Inlet Silencer by others

• Bellows (TD – Silencer)

• Transition Duct (After pre assy at ground

level)

INSTALLATION

Filter Section and Weather

Hoods

• Pre Assy of weather hoods

and bolted to Filter section at

ground level

• As with the EVAP there were

three lifts for the Filter Module

sections

• Note EVAP media and drift

panels not installed.

INSTALLATION

Plumbing

• Installation of the

pipework, pumps,

flow valves etc for

EVAP cooler

• Installation of pump

and connection of

services.

INSTALLATION

Electrical Kit

• Control panel

• Junction Box

• ΔP Filter Section

• ΔP Evap Section (Absolute)

• ΔT Inlet air temp

• Conductivity (Water Quality)

• Internal Lighting

INSTALLATION

Filter Elements

• Upstream Filter elements Installed

Evap Drift Pads and Media

• Evap media installed last ensuring no

damage is caused during the installation

stage

WHAT WENT WRONG

NOT A LOT

• Stairway Handrails not to Australian

standard

• Reduced wall height of Evap dam

walls due to turbulence.

• Access door locks

WHAT WENT RIGHT

A LOT

• Cooling efficiency -

88%

• Donaldson met the

required efficiency

• Pressure Drop 1.5”

w.g.

• Pressure Drop was

measured below the

required 1.5” w.g.

• Delivery was to the

program

PERFORMANCE

Summer Capacity

• Increases confirmed to be approx 4-5MW per GT

• Total 50-60MW across the plant.

QUESTIONS?