Distance - Computer Simulation of Gas Turbines: Performance Monitoring, Maintenance and Profit Optimization, Power Augmentation, Profits, Revenue and Life Cycle Cost Analysis (1.8 CEU'S)

Course Code: MEC080d

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Looking for professional development but do not have the time to take off from work?
Looking for refresher course on specific engineering topics and cannot find an intensive course to serve your needs?
This may be your ideal Professional Development course!

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Duration:

This course is approximately 4-5 weeks in duration.

Learning Method:

The PDDP program is more of a self-guided learning style.
You are required to read the notes and materials given, complete the follow-up assignments on your own, send in your questions prior to your 1 hour webinar meeting (if required) and be involved in live discussion via the internet.
Once you have completed the course, you will receive a certificate of completion

Description

This course is part of the Power Generation Specialist Certificate program. Although it can also be taken on its own.

This course provides in-depth understanding of computer simulation of gas turbines under steady-state and transient conditions. The selection considerations and applications of co-generation and combined cycles are also covered in this course. The analysis performed by gas turbine simulators provides the following benefits:

Allow the operator to extend the gas turbine operating period by avoiding unnecessary outages and maintenance activities.
Determination of essential gas turbine maintenance activities to reduce the duration of the outage.

The simulation program is capable of simulating the following parameters to determine their effects on gas turbine performance, turbine creep life, environmental emissions, gas turbine life cycle cost, revenue, and profitability: variations in ambient temperature and pressure, inlet and exhaust losses, engine deterioration, different faults, power augmentation methods including peak mode, and water injection, control system performance (including proportional offset, integral windup, and trips), variations in the fuel type (natural gas, diesel, etc), variations in maintenance techniques and frequency, variations in many key parameters.

The simulation program is also capable of trending the following:

Many gas turbine key parameters such as exhaust gas temperature, speed, etc.
Compressor characteristics, and its operating point during engine transients.

These trends can also be provided as bar charts. The simulated data can be exported to other Window packages such as Excel spreadsheets, etc. Many simulation exercises are included to describe how the simulation program should be used for different scenarios including co-generation and combined cycle plants.

Delegates are also encouraged to bring the operational data of their gas turbines. The instructor will be able to perform simulation of their plants to reduce unnecessary maintenance activities, optimize the profits, and minimize environmental emissions.

De-regulation of the electricity markets is sweeping across the world. There will be increasing opportunities for highly efficient power generating plants, such as combined cycle and co-generation, to compete against the older plants of established utilities. These new plants are environmentally friendly and more than twice as efficient as the older fossil and nuclear generating plants. Independent Power Producers and utilities are planning to construct additional combined cycle and co-generation plants due to their short construction lead-time and low capital investment.

Objective

To provide a comprehensive understanding of computer simulation of gas turbines, as well as their selection criteria, operation and maintenance requirements, and economics. Participants will develop a good understanding of gas turbines and their numerous advantages.

Who Should Attend

Engineers of all disciplines, managers, technicians, maintenance personnel, and other technical individuals.

Special Feature

The following is included, in digital form, with your registration:

A book (800 pages) titled “POWER PLANT EQUIPMENT OPERATION AND MAINTENANCE GUIDE” published by McGraw-Hill in 2012 and authored by the instructor.
A manual (200 pages) authored by the instructor covering additional information about gas turbines and computer simulation.

The PDDP Distance Education program works as follows:
Once you register for this course, you will be sent a login username and password for our online distance website.
You will receive the course notes in hard copy through the online website, you will receive a set of notes each week covering the course material.
A one hour video-conference session will be conducted by your instructor each week (if required). The objective of this session is to assist in solving the assignments, as well as answer student questions that should be sent to instructor early enough prior to the meeting time. In addition with being able to communicate with the instructor, you will also be able to communicate with other students in the same class and watch their questions being answered as well. (A high speed internet connection is strongly recommended for this feature).
Each set of exercises can be completed and submitted by the indicated date and your completed exercise will be marked online and and returned by your instructor.
To gain the most from your course, it is highly recommended that you participate fully in all discussions and exercises. Please remember that each course has a form of quiz or exercise at the end to test your understanding of the material. You will be informed of these dates when you receive the course schedule.
*Course commencement date is subject to instructor availability.

Philip Kiameh

Philip Kiameh, M.A.Sc., B.Eng., D.Eng., P.Eng. (Canada) has been a teacher at University of Toronto and Dalhousie University, Canada for more than 24 years. In addition, Prof Kiameh has taught courses and seminars to more than four thousand working engineers and professionals around the world, specifically Europe and North America. Prof Kiameh has been consistently ranked as "Excellent" or "Very Good" by the delegates who attended his seminars and lectures.

Prof Kiameh wrote 5 books for working engineers from which three have been published by McGraw-Hill, New York. Below is a list of the books authored by Prof Kiameh:

Power Generation Handbook: Gas Turbines, Steam Power Plants, Co-generation, and Combined Cycles, second edition, (800 pages), McGraw-Hill, New York, October 2011.
Electrical Equipment Handbook (600 pages), McGraw-Hill, New York, March 2003.
Power Plant Equipment Operation and Maintenance Guide (800 pages), McGraw-Hill, New York, January 2012.
Industrial Instrumentation and Modern Control Systems (400 pages), Custom Publishing, University of Toronto, University of Toronto Custom Publishing (1999).
Industrial Equipment (600 pages), Custom Publishing, University of Toronto, University of Toronto, University of Toronto Custom Publishing (1999).

Prof. Kiameh has received the following awards:

The first "Excellence in Teaching" award offered by the Professional Development Center at University of Toronto (May, 1996).
The "Excellence in Teaching Award" in April 2007 offered by TUV Akademie (TUV Akademie is one of the largest Professional Development centre in world, it is based in Germany and the United Arab Emirates, and provides engineering training to engineers and managers across Europe and the Middle East).
Awarded graduation “With Distinction” from Dalhousie University when completed Bachelor of Engineering degree (1983).
Entrance Scholarship to University of Ottawa (1984).
Natural Science and Engineering Research Counsel (NSERC) scholarship towards graduate studies – Master of Applied Science in Engineering (1984 – 1985).

Prof. Kiameh performed research on power generation equipment with Atomic Energy of Canada Limited at their Chalk River and Whiteshell Nuclear Research Laboratories. He also has more than 30 years of practical engineering experience with Ontario Power Generation (formerly, Ontario Hydro - the largest electric utility in North America).

While working at Ontario Hydro, Prof. Kiameh acted as a Training Manager, Engineering Supervisor, System Responsible Engineer and Design Engineer. During the period of time that Prof Kiameh worked as a Field Engineer and Design Engineer, he was responsible for the operation, maintenance, diagnostics, and testing of gas turbines, steam turbines, generators, motors, transformers, inverters, valves, pumps, compressors, instrumentation and control systems. Further, his responsibilities included designing, engineering, diagnosing equipment problems and recommending solutions to repair deficiencies and improve system performance, supervising engineers, setting up preventive maintenance programs, writing Operating and Design Manuals, and commissioning new equipment.

Later, Prof Kiameh worked as the manager of a section dedicated to providing training for the staff at the power stations. The training provided by Prof Kiameh covered in detail the various equipment and systems used in power stations.

Professor Philip Kiameh was awarded his Bachelor of Engineering Degree "with distinction" from Dalhousie University, Halifax, Nova Scotia, Canada. He also received a Master of Applied Science in Engineering (M.A.Sc.) from the University of Ottawa, Canada. He is also a member of the Association of Professional Engineers in the province of Ontario, Canada.

Review of Thermodynamics Principles

The First Law
The Enthalpy
The Closed System
The Cycle
Property Relationships
Perfect Gases
Imperfect Gases
Vapor-Liquid Phase Equilibrium in A Pure Substance
The Second Law of Thermodynamics
The Concept of Reversibility
External and Internal Irreversabilities
The Concept of Entropy
The Carnot Cycle

The Turbine Governing Systems

Introduction
Governor Characteristics
Subsidiary Functions
Acceleration Feedback
Unloading Gear
Governor Speed Reference
Closed-Loop Control of Turbine Electrical Load
Overspeed Testing
Automatic Run-up and Loading Systems
Electronic Governing
Reheater Relief Valves
Hydraulic Fluid System
Filtration

Gas Turbine fundamentals

Gas Turbine cycles
Ideal cycles
Waste Heat Recuperators
Reheat Cycle
Combined Cycle Plants

An overview of Gas Turbines

Introduction
The Brayton Cycle
Industrial Heavy-Duty Gas Turbines
Aircraft-Derivative Gas Turbines
Medium-Range Gas Turbines
Small Gas Turbines
Major Gas Turbine Components
Compressors
Axial-Flow Compressors
Centrifugal Compressors
Compressor Materials
Two-Stage Compression
Regenerators
Combustors
Tubular (side combustors)
Can-annular and Annular
Combustor Operation
Turbines
Axial-Flow Turbines
Radial-Inflow Turbines
Heat Recovery Steam Generators
Total Energy Arrangement
Gas Turbine Applications
Comparison of Gas Turbines with Other Prime Movers

Gas Turbine Design

Introduction
Compressors
Compressor Off-Design Performance
Low rotational speeds
High rotational speeds
Combustors
Principles of Operation
Combustor Design Details
Cooling Provisions
Transition Housing and Ignition
Turbines
Turbine operation
Blade cooling
Types of cooling
Effectiveness of The Various Cooling Methods
Materials
Performance Degradation

Gas Turbine Calculations

Regenerative-Cycle Gas-Turbine Analysis
Calculation Procedure

Dynamic Compressors Technology

Introduction
Centrifugal compressors technology
Axial compressors overview

Gas Turbine Compressors

Centrifugal Compressors
Principle of Operation
Compressor Characteristics
Axial Flow Compressors

Compressor Auxiliaries, Off-Design Performance, Stall, And Surge
Introduction
Compressor auxiliaries
Compressor off-design performance, low rotational speeds, high rotational speeds.
Performance degradation.

Centrifugal Compressors – Components, Performance Characteristics, Balancing, Surge Prevention Systems and Testing

Introduction
Casing Configuration
Construction features
Diaphragms
Interstage seals
Balance piston seals
Impeller Thrust
Performance Characteristics
Slope of the centrifugal compressor head curve
Stonewall
Surge
Off-design Operation
Rotor Dynamics
Rotor Balancing
Surge Prevention Systems
Surge Identification
Liquid Entrainment
Instrumentation
Cleaning Centrifugal Compressors
Appendix A (Boundary Layer)
Definition
Description of the Boundary Layer
Separation; Wake

Dynamic Compressors Performance

Description of a centrifugal compressor
Centrifugal compressor types
Compressors with horizontally-split casings
Centrifugal compressors with vertically-split casings
Compressors with bell casings
Pipeline compressors
Performance limitations
Surge limit
Stonewall
Prevention of surge
Anti-surge control systems

Gas Turbine Combustors

Introduction
Combustion Terms
Combustion
Combustion Chamber Design
Flame Stabilization
Combustion and Dilution
Film Cooling of the Liner
Fuel Atomization and Ignition
Gas Injection
Wall Cooling
Wall-Cooling Techniques
Combustor Design Considerations
Air Pollution Problems
Smoke
Hydrocarbon and Carbon Monoxide
Oxides of Nitrogen
Typical Combustor Arrangements
Combustors for Low Emissions
Combustors for Small Engines (less than 3 MW)
Industrial Chambers
Aeroderivative Engines

Axial-Flow Turbines

Introduction
Turbine Geometry
Degree of Reaction
Utilization Factor
Work Factor
Impulse Turbine
The Reaction Turbine
Turbine Blade Cooling Methods
Convection Cooling
Impingement Cooling
Film Cooling
Transpiration Cooling
Water Cooling
Turbine Blade Cooling Designs
Convection and Impingement Cooling/Strut Insert Design
Film and Convection Cooling Design
Transpiration Cooling Design
Multiple Small-Hole Design
Water-Cooled Turbine Blades
Cooled-Turbine Aerodynamics

Gas Turbine Materials

Introduction
General Metallurgical Behaviors in Gas Turbines
Creep and Rapture
Ductility and Fracture
Thermal Fatigue
Corrosion
Gas Turbine Blade Materials
Turbine Wheel Alloys
Coating for Gas Turbine Materials

Gas Turbine Lubrication and Fuel Systems

Gas Turbine Lubricating Systems
Cold Start Preparation
Fuel Systems
Liquid Fuels
Water and Sediment
Carbon Residue
Trace Metallic Constituents and Sulphur
Vanadium
Lead
Sodium and Potassium
Calcium
Sulphur
Gaseous Fuels
Gas Fuel Systems
Liquid Fuel Systems
Starting
Intake System
Compressor Cleaning

Gas Turbine Bearing and Seals

Bearings
Bearing Design Principles
Tilting-Pad Journal Bearings
Bearing Materials
Bearing and Shaft Instabilities
Thrust Bearings
Factors Affecting Thrust Bearing Design
Thrust Bearing Power Loss
Seals
Noncontacting Seals
Labyrinth Seals
Ring (Bushing) Seals
Mechanical (Face) Seals
Seal Systems

Gas Turbine Instrumentation and Control Systems

Vibration Measurement
Pressure Measurement
Temperature Measurement
Thermocouples
Resistive Thermal Detectors
Control Systems
Speed Control
Temperature Control
Protective Systems
Startup Sequence
Starting Preparations
Startup Description
Shutdown
Fuel System
Baseline for Machinery
Mechanical Baseline
Aerothermal Baseline
Data Trending
Compressor Aerothermal Characteristics and Compressor Surge
Failure Diagnostics
Compressor Analysis
Combustor Analysis
Turbine Analysis
Turbine Efficiency
Mechanical Problem Diagnostics
Instrumentation and Control Systems of a Typical Modern Gas Turbine
Modern Gas Turbine Control Systems
Closed-Looped Controllers
Protective Systems
Permissives (Interlocks)
Liquid Fuel Supply
Start-up Sequence of the Gas Turbine
Cranking Phase
Acceleration Phase
Synchronization Phase
Loading Phase
Operation Phase
Inlet Guide Vanes
Compressor Bleed Valves
Transmitters

Gas Turbine Performance Characteristics

Thermodynamic Principles
Thermodynamic Analysis
Factors Affecting Gas Turbine Performance
Air Extraction
Performance Enhancements
Inlet Cooling
Steam and Water Injection for Power Augmentation
Peak Rating
Performance Degradation
Verifying Gas Turbine Performance

Gas Turbine Operating and Maintenance Considerations

Introduction
Gas Turbine Design Maintenance Features
Borescope Inspection
Major Factors Influencing Maintenance and Equipment Life
Starts and Hours Criteria
Service Factors
Fuel
Firing Temperature
Steam/Water Injection
Cyclic Effects
Air Quality
Combustion Inspection
Hot-Gas-Path Inspection
Major Inspection

Gas Turbine Emission Guidelines and Control Methods

Background
Emissions From Gas Turbines
General Approach For a National Emission Guideline
NOX Emission Target Levels
Power Output Allowance
Heat Recovery Allowance
Emission Levels For Other Contaminants
Carbon Monoxide
Sulphur Dioxide
Other Contaminants
Size Ranges For Emission Targets
Peaking Units
Emission Monitoring
NOX Emission Control Methods
Water and Steam Injection
Selective Catalytic Reduction (SCR)
Dry Low-NOX Combustors

Computer Simulation of Gas Turbines

Introduction
Effects of ambient temperature on gas turbine performance
Effects of ambient pressure on gas turbine performance
Simulation of effects of component deterioration on engine performance
Compressor fouling
Turbine damage
Power Augmentation
Peak rating
Power augmentation by water injection
Simulation of engine control system performance
Proportional-integral-derivative control loop
Proportional action
Proportional and integral action
Proportional, integral and derivative action
Signal selection
Optimizing Exhaust Gas Temperature (EGT)
Trips
Variable Inlet Guide Vanes (VIGV’s) control
Profits, Revenue and Life Cycle Cost Analysis
Effects of ambient temperature and pressure on life cycle cost
Power augmentation
Performance deterioration
Maintenance cost
Non-Dimensional Analysis
Application of Flow Compatibility Equation During Hot End Damage
Application of Flow Compatibility Equation When the Ambient Temperature Drops
Computer Simulation Applications
Computer simulation applications for several gas turbine installations
Computer simulation applications for several co-generation and combined cycle plants

Computer Simulation of Gas Turbines and Combined Cycles Exercises and Solutions

1 - Effects of ambient temperature and pressure on engine performance

Determine the maximum generator power, gas turbine shaft power and thermal efficiency for the engine when operating at ISO conditions. What is the creep life usage of the turbine? ISO conditions refer to an ambient temperature and pressure of 15 degrees Celsius and 1.013Bar respectively and zero inlet and exhaust losses.

What limits the power output from the gas turbine?

Determine the emissions from the gas turbine and hence calculate the amount of NOx, CO and CO2 in Tonnes/year.

The engine operating at site has the following conditions.

Ambient temperature 15 degrees Celsius
Ambient pressure 1.013 Bar
Inlet and exhaust loss of 100 mm water gauge

Determine the parameters in exercise 1 above and calculate the percent changes in the parameters when operating at site rated conditions. Explain the changes in the turbine life usage.

3 - Determine the percent changes in the parameters in exercise 1 when

The ambient temperature is 30 degrees Celsius
The ambient temperature is zero degrees Celsius
The ambient temperature is –15 degrees Celsius

What limits the power output from the gas turbine when operating at these ambient temperatures?

Repeat this simulation exercise using the control system option 2. Comment on the operation of the variable inlet guide vane (VIGV) at these ambient conditions.

4 - When operating at site rated conditions as stipulated in exercise 2, determine the parameters in exercise 1 when the ambient pressure is 0.975 Bar and calculate the percent change from the values determined in exercise 1 above.

5 - When the required power output from the generator is 37MW and the ambient pressure and temperature are 0.975 Bar and 15 degrees Celsius respectively. Determine the thermal efficiency of the gas turbine. If the ambient pressure increases to 1.03 Bar explain the why the thermal efficiency decreases and explain the changes in the turbine creep life usage and emissions.

6 - Produce a graph describing the maximum gas turbine power output with ambient temperature indicating what engine parameter restricts the capacity of the gas turbine at different ambient temperatures. Also, determine the ambient temperature when the engine power output is limited by exhaust gas temperature and maximum power limit. The variation in ambient temperature should be from 30 to –17 degrees Celsius in steps of 10 degrees.

7 - Increased filter loss and low ambient pressure reduces the compressor inlet pressure. When the engine developing 37MW of electrical power explain difference in thermal efficiency when the compressor inlet pressure decreases due to a high filter loss and low ambient pressure.

8 - Use the gas turbine to demonstrate the benefits of a closed cycle gas turbine.

9 - If this engine operates as a closed cycle gas turbine using air as the working fluid with a system pressure is 5 Bars, estimate the maximum power output from the gas turbine. What is the thermal efficiency of the closed cycle gas turbine? Assume a compressor inlet temperature of 15 degrees Celsius.

10- A factory is being planed and it has been decided that the plant shall generate its own electrical power of 32 MW with the prospect of selling any surplus power to the grid. Two possible sites are suitable. The average ambient temperature and pressure of the first site is 30 Celsius and 1.013 Bar respectively. The second site is at a higher elevation and the average ambient temperature and pressure is 15 degrees Celsius and 0.975 Bar respectively. Use the simulator to determine the most suitable site based on engine performance. Assume an inlet and exhaust loss of 100 mm water gauge respectively.

Economic and Technical Considerations for Combined Cycle Performance Enhancement Options

Introduction
Economic Evaluation Technique
Output Enchancement
Gas Turbine Inlet Air Cooling
Evaporative Cooling
Evaporative Cooling Methods
Evaporative Cooling Theory.
Wetted-Honeycomb Evaporative Coolers
Water Requirements for Evaporative Coolers
Foggers
Evaporative Intercooling
Inlet Chilling
Inlet Chilling Methods
Off-Peak Thermal Energy Storage
Gas Vaporizers of Liquefied Petroleum Gases
Power Augmentation
Gas Turbine Steam/Water Injection
Supplementary Fired HRSG
Peak Firing
Output Enhancement Summary
Efficiency Enhancement
Fuel Heating
Conclusion

Selection of the Best Power Enhancement Option for Combined Cycle Plants

Plant description
Evaluation of inlet-air pre-cooling option
Evaluation of inlet-air chilling option
Evaluation of absorption chilling system
Evaluation of the steam and water injection options
Evaluation of supplementary firing in HRSG option
Comparison of all power enhancement options

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