DONALDSON AUSTRALASIA PTY LTD Valley Power Upgrade – Air Inlet Filter House and Defective Cooling with Peter Brighton 14 th Annual Gas Turbine Systems Conference – Hilton Hotel Brisbane 30 th October, 2013
May 25, 2015
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?