USE OF AN AIRCRAFT TURBINE IN AN INDUSTRIAL POWER PLANT IN CONTINUOUS OPERATION

Ziel

To install an aircraft-derivative gas turbine of 35 MW in the contractor's power plant with the necessary alterations and to operate the system continuously and at full load under industrial conditions.
The "Dow Chemical GmbH", now "Dow Deutschland Inc.", has now accumulated more than 170 000 operating hours with this type of aeroderivative gas turbine. Dow replaced in three consecutive years, starting 1984, three FIAT TG 20 gas turbines with LM 5000 aeroderivative gas turbines.
The availability, counted as three available for synchronization of the electric generator has been at 89,4% of time of all three units.
The guaranteed electrical efficiency of the manufacturer of 35,4% lower heating value (gas generator only) has been exceeded all the time, even at the high time engine with greater than 47750 operating hours.
However the reliability of the engines is below that published by the manufacturer and the packagers despite all efforts. Dow has had in total nineteen unexpected engine failures.
Classifying the root causes of the unexpected engine failures one can find four main areas.
a) High pressure compressor at the beginning
b) Bearings especially hot end side
(still a problem)
c) Fuel Nozzles at the beginning, two major
high pressure turbine damages in 1987
d) Combustor with water injection for NOx-abatement
limited service time
Now with 47 LM 5000 sets in operation worldwide, the data base is expanded and problems can be solved in much faster time frames than in the beginning with less than ten turbines in operation.
The power turbine manufactured by IHI had some minor problems with the seals and with the transition duct between LM 5000 and the power turbine. In general there was a close to trouble free service.
The air filtration for the new set had been designed and built by "American Air Filters, "AAF" and is now in operation with filters supplied by 'CAMFIL".
Air filtration for this type of turbine is a high important item for engine reliabilityand the high pressure compressors are now running trouble free.
Operation between shut down for compressor wash is now one year.
The energy requirement of the chemical industry is changing towards more electricity and less steam, a balance which for conventional power plants is difficult to achieve in an energy-efficient manner.
This project will demonstrate that the use of aircraft-derivative gas turbines in a conventional power plant can improve the electricity output by 30% while reducing the steam production.
The system comprises first a gas generator which consists of 2 compressors of increasing power built in-line, a combustor and 2 turbines of decreasing power equally built in-line. This is linked to a 3-stage power turbine which drives the electricity generator. The exhaust gases of the power turbine are ducted into a heat recovery boiler for steam production. The gas generator is the critical part as the turbine. In contrast to industrial turbines, aircraft turbines are normally not used in continuous operation and at full-load during aircraft take-off.
This new aircraft-derivative gas turbine willbe installed in place of an existing industrial gas turbine in the power station of Dow Chemical Gmbh in Stade.
The financial EEC participation of 2,330,000.-DM is limited to the innovative part of the project i.e. the construction of the foundation of the turbine, the assembly of the turbine unit and the construction of the air-inlet channel and exhaust channel as well as to the measuring phase.

Programm/Programme

ENG-ENALT 2C - Programme (EEC) of demonstration projects relating to the exploitation of alternative energy sources and to energy saving and the substitution of hydrocarbons, 1983-1985

Thema/Themen

3.4 - ENERGY INDUSTRY

Aufforderung zur Vorschlagseinreichung

Data not available

Finanzierungsplan

DEM - Demonstration contracts

Koordinator

DOW DEUTSCHLAND INC.

EU-Beitrag

Keine Daten

Adresse

POSTFACH 120
2160 STADE
Deutschland

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