constructability & maintainability seminar...drain piping compartment space heaters jack stand...

Constructability & Maintainability Seminar

7HA Gas Turbine

* Trademark of General Electric Company

GE Proprietary and Confidential

2 7HA Constructability Seminar

3/23/2014 Comparative statements refer to GE technology unless otherwise stated. © 2013 General Electric Company. All rights reserved.

GT Accessory Modularization Overview

Fuel Control Module Air Extraction Module, Lower

Air Extraction Module, Left

Upper Enclosure Module, Left

Upper Enclosure Module, Right

Air Extraction Module, Right

GT Drains Module



Modularization Example…Cooling & Sealing Air Build Scaffolding

Install piping and piping supports

Install ship loose valves in piping

Build enclosure around piping, mount junction boxes, cut piping penetrations through walls

Route instrument air tubing, electrical wiring

& conduit to wall of enclosure

Complete water wash drain piping (EPC scope of design & supply within enclosure)

Commission valves and instrumentation

Insulate all piping

Install turbine maintenance grating and handrails

1

2

3

5

6

7

8

4

9

7F.03 Cooling and Sealing Air

7HA.01 Modularized Design

1

2

3

Install modules

Install piping between GT and modules

Insulate field installed piping

7HA 7F.03



Air Extraction Module, Lower

Purge air cooler

Water wash drain piping

Compartment space heaters

Jack stand

•Purge air cooler complete with water control valve and piping

• Jack stand integrated as piping support to prevent from unnecessary piping removal during maintenance



Fuel Control Module

Gas Fuel Control Valves

Liquid Fuel Control Valves

Valve Removal Trolley

•Valve removal trolley is capable of lifting all valves and dropping them in front of double doors for easy removal

•Module size does not change for gas only units, remains as open area

Grating walkways between valves for maintenance access



Quick Disconnect Flanges Gas Fuel Manifolds

Liquid Fuel Manifolds

104 quick release flanges 6 WW drain flanges

32 quick release flanges

24 SAE 4-bolt flanges



Air Extraction Module, Left

• Cooling and sealing air piping • Compressor bleed valve • Inlet bleed heat valve • Stage 2 and 3 nozzle cooling valves • Integrated grating for maintenance

access • Handrails (not shown) included



Air Extraction Module, Right

Stage 2 Nozzle

cooling valve

Over Board Bleed valve (FSFL test hardware only)



GT Drains Module

Water wash supply

control valves

Water wash

drain valves

False start drain valves

Simplified

interface points

Removable grating and sill for roll-in access

through double doors



Combustion Can Maintenance Access

Maintenance area reserved to allow can removal from below

Width: 5’ Height: 6’ Length: 12’

Double door with removable sill for “roll-in roll out” access



Drains Module Maintainability

• All valves are accessible through access door & platform • All manual drain valves are color coded and tagged” to align

with the off-line water wash sequence.

GT DRAIN

MODULE

False Start Drain Valves

Access to False Start Drain Valves

Access to Manual WW Drain Valves

Access to WW supply

Valves

2.5’

Front End

Manual WW Drain Valves

WW supply Valves



Gas Fuel Scrubber and Dewpoint Heater

Close-coupled scrubber reduces

EPC supplied SS piping

Dewpoint heater design eliminates

gas pressure drop associated with

startup heating

Start-up Heater

(GE Supplied)

Simplified Customer – GE

Transfer Point at Inlet to Scrubber



External Modules

Lube Oil

Module

Liquid Fuel

Filtering

Inlet Plenum

Load Coupling

Guard



Lube Oil Piping

Simplified lube oil flushing developed with field engineers reduce setup time

Enclosures and Ventilation



Ventilation

Single extraction & instrumentation duct

Ventilation inlets and dampers included in modules

GT Insulated at site by GE or GE supervision (Union Sites)

Modules ship with insulation pre-installed

Fans are moved aft over exhaust to enable simpler roof design and easier maintenance access



GT Enclosure Maintenance Provisions

Deck height set below

turbine centerline to

allow for easy bolt access

Maintenance access points for pneumatic

hoses and power cords

Ladders and Handrails

incorporated in modules

Removable grating and

bracing allow valves to

be pulled up to main deck



Clean Roof

Single Ventilation Extraction (no removal required)

Exhaust Frame and #2 Bearing Blowers

GT Compartment Ventilation Fans

CI HGP Maj



Load Compartment & Load Coupling Guard

No separate off base load compartment

Load Compartment ventilation fans (2) and silencer eliminated

Self-Ventilating Load Coupling Guard

Shaft windage used to dissipate heat generated by coupling

Natural ventilation path for hydrogen dissipation when not running

Current 7F.03 Design

New 7HA.01 Design

Ventilation CFD



Instrument Air

Instrument air tubing to valves pre-installed in modules and routed to customer connection



Inlet Filter House and IBH

2-Pipe IBH Manifold

Simplified Interconnect Piping by GE (no bellows)

IBH Control Valve modularized into GT

enclosure

All IBH piping is in GE

scope of supply



Inlet Bleed Heat Simplification

Previous 7F Design

Trombone Pipes

Piccolo Pipes

2 Horizontal

Distribution Pipes

Simplified 7HA Design

All piping field installed

Extensive welding and x-ray test required

Welding inside duct required for supports

Internal piping shipped pre-installed

6 field welds and standard 10% x-ray testing

No welding inside duct required

Overmixed Proper Mixing



Interface to turbine hall for indoor installations

Rotor Removal Clearance

Interface to Indoor Building

Side View

Top View

Extension of GT enclosure roof allows for simplified interface to

building and reduced ventilation ducting by EPC

Sloped inlet allows for lower

crane and building height

Electrical



Electric actuation… no hydraulics

Electric control valves Gas fuel Purge Liquid fuel Water injection

Factory wired to controllers

220VDC actuation replaces 125VDC for power

24 VDC for signal

IGV: two electric actuators

VSV: two electric actuators control

first three stages of vanes

Compressor vane actuators

Connectorized wire harnesses supplied by

GE between actuator and control cabinet



IGV & VSV Maintenance Simplification

Connectorized Digital Valve Positioner Cabinet for electrically actuated valves IGV (2) & VSV (2) Gas Fuel Control (4) Liquid Fuel Control (3)

Plug and Play electrical

design to reduce

installation and

commissioning time

Roxtec cable sealing for enclosure penetrations

Hydraulic tubing and

servos eliminated



• Cable tray instead of conduit

• Electrical pre-wired for accessory modules

• Exposed run rated cable to allow for free length at device termination

• 125 VDC power level has been eliminated (replaced by 24 VDC for low power signals and 220 VDC for high power level)

~50% reduction in # of JBs.

~70% reduction in # of field terminations.

BEFORE – Conduit AFTER – Cable Tray

Electrical Design Highlights

Field installed, cut, and

routed conduit is replaced

by pre-installed cable tray



FFB minifast connectors at T/Cs, transmitters, segment

protectors and linking devices for Plug and Play wiring design.

Example FFB Network Topology (Lube Oil)

Connectorized FBSPs - Plug and Play Design



• Aspirated IR design for GT

enclosure, aspirated cat

bead technology for

generator and generator

collector enclosures.

• New technology reduces #

of false trips which was a

nuisance with the older

technology. It is also

immune to poisons which

was a major limitation of

the BN cat bead sensors.

• New design can tolerate

tighter LEL settings and

has a lower calibration

frequency.

Haz Gas Detection System Design Highlights



FFB Constructability and cost Reference project: 50 Hz Single Shaft CC

Source: GE detailed plant configurations & funded study

Impact to plant construction cost Percent reduction

>60%

>80% >80%

>50%

Field control element coverage (total plant)

FOUNDATION fieldbus CANOpen Profibus Hardwired

Fire Protection



Fire Protection System – Water Mist

Customer located skid: Tubing to each zone up to 150ft.

Zone 1 – Turbine Compartment

Zone 2 – #2 Bearing Tunnel

Zone 3 – Lube Oil Skid

Water mist is standard for fire protection instead of CO2.

• Meets NFPA 750 standard

• FM Approved system

• Gas pump unit (GPU) is driven by compressed air cylinders to drive water to the nozzles.

• Discharge solenoid valve open on fire detection or manual release.




Water Mist vs CO2

• SAFETY - Eliminates personnel risks. Mist insulates personnel from thermal

radiation. No Risk of Asphyxiation. C02

also causes carbonic acid build up in

lungs.

• SYSTEM EFFECTIVENESS - Eliminates

suppression failures from loss of

enclosure tightness (37% of CO2 system

failures due to C02 system leaks causing

inability to reach required concentrations). Water Mist remains effective with open

doors.

• EQUIPMENT DAMAGE - Reduces fire damage potential by eliminating

discharge delay (30 Seconds). Potential

spread of fire reduced.

• COST OF OWNERSHIP - Reduces long term cost of ownership, eliminates

periodic full discharge concentration tests

following major GT maintenance

(Currently $24,000 per re-test).

• ENVIRONMENT – Eliminates hazards to

environment due to C02 Production.




Field installation scope

Water Mist CO2

Skid Customer located

Interconnect Piping

1 line of tubing per zone (3 total)

3 lines of piping per zone (9 total)

Compartment Electrical Devices

Thermocouples, manual release stations, strobes/horns

Control Panel Installed in PEECC

Commissioning Functional test (full discharge not needed)

Full discharge concentration & enclosure

tightness test

Liquid Fuel System Design



Liquid Fuel System: New Design Legacy Design New Design

Atomization Atomizing Air Pressure Atomized

NOx abatement Water injection Pre-mixed Water & Fuel

Anti-coking Recirculation/N2 Purge Water purge

Purge credit Secondary Design Features Inherent to Design

Purge Cooled Air Purge Water Block



Simplified EPC Scope

Filtration skid

By GE

Piping by GE

Liquid Fuel and Water Injection pumps by GE

Interconnect

Piping by EPC

7F.03 Skids Liquid fuel forwarding Water injection (A035) Fuel heating (E041) Fuel management spool piece (A245) Liquid Fuel and Atomizing Air (A162) 7HA Skids Liquid fuel pumping Water injection pumping Liquid fuel and Water Injection Filtering AM10 Fuel Control Module (shared with gas)

Fuel forwarding pumps are no longer required for new design

4” if < 1400 ft



Labor intensive site installation Modularized manifolds with quick disconnects at mid-line

Pressure Atomized LF LF w/ Atomizing Air

Simplified field installation & maintenance



Pressure Atomized LF LF w/ Atomizing Air

• Many potential leak points • Labor intensive for CIs

• Flanges minimized, no tube fittings • Only 2 tubes to remove for CI

On-base Piping



6 endcover connections 2 Valves on endcover

2 endcover connections No valves on endcover

LF w/ Atomizing Air

Simplified field installation

Pressure Atomized LF



Pilot circuit effective area during coking test

Water Flush

Air Purge

Liquid Fuel System: Air Purge vs. Water Purge

• Pilot lost 48% of effective flow area in 50 cycles with air purge at 1.2 pressure ratio.

• Pilot effective area steady after 90 cycles in cartridge with water flush.

• No evidence of main circuit clogging in either case, but air purge test terminated at 50 cycles. Mains circuits are 8 times larger than pilots.

• Coked pilot made a marginal spray, but – no effective area recovered after water flush.



Flush Effectiveness Testing - Main

Coupon Testing

Filled/Brushed, Covered & Cooked 1 hr @ 425 °F

UV Dye Flush Testing

Main Fuel Valve: Test Point #1 Main Fuel Valve: Test Point #7

Flush/Coke Testing

Main Flushed per Test Point #7, cooked 2 hrs @ 425 °F (3x total)

Conclusion • Final flush test point conservative

compared to actual worst-case main flush (shutdown)

• Main flush strategy yields very good results according to dye and coke tests



Liquid Fuel Installation Savings

*GE installation hour estimates are based on field feedback for various 7F-3 sites

* 7HA

7HA

Shipping



GT Shipping Configuration

• All combustion cans ship installed on unit

• Inner two fuel manifolds and flex hoses ship installed

• Shipping beam has bolted joint, forward stub used for fuel gas piping manifold support

Summary



Reduction in Field Welds

MLI 7F.03 7HA.01 Reference Drawings

Notes

0909 74 35 102T0554 Modularized CSA inside GT enclosure.

0972 33 6 146E1221 Simplified exhaust frame cooling path, fewer supports on roof.

969G 31 16 119E6563 Greatly simplified and shortened interconnect piping.

0962 2 2 146E5542 Mostly spool pieces with flex hoses.

969A 39 32 146E3071 Piping will be hung from enclosure, less supports to ground

0905 13 10 143E5962 Welds completed on pipe in pipe and prefit up at supplier

0906 34 30 101T3905 Common supports with main lube oil supply

0907 13 13 146E3514 Similar to 7FA.03

969M 37 0 141E7353 All 969M eliminated with electric IGV implementation.

0965 2 0 102T1571 AA eliminated as part of new pressure atomized LF system.

969D 17 0 102T0837 AA eliminated as part of new pressure atomized LF system.

0924 52 9 119E6562 & 102T3794

Modularized IBH piping

0920 43 20 146E3255 Modularized Drains

0979 6 6 138E5391 Same as 7FA.03

0976 18 16 138E6029 Simplified supports

0918 24 10 146E3136 Purge for Gas Fuel side only, LF purges w/ water through manifold

0961 1 12 137E2503 Mostly tubing before. Now some piping.

969L 33 0 141E7765 Piping eliminated as part of pressure atomized LF system.

969C 30 6 146E6343 Vastly simplified LF interconnect, no tubing, 2 lines now.

0968 5 5 100T7549 Same as 7FA.03

0953 10 10 100T5598 Same as 7FA.03

0915 8 0 102T0095 All 0915 piping eliminated.

525 238 54% Reduction in Field Welds



Field Installed Valves

MLI System 7F.03 7HA.01 Notes

0417 Cooling and Sealing Air 13 0 4 eliminated, 9 in modules

0422 Gas Fuel 2 1 SSOV Vent Valve in module

0425 Atomizing Air 1 0 eliminated manifold drain valve

0432 Inlet Bleed Heat 2 0 IBH Control Valve Modularized, manual isolation valve eliminated

0434 Lift Oil 4 0 Lift Oil flow control valves in interconnect piping

0442 Water Wash & FSD 17 0 FSD Valves and WW Drain Valves modularized

0477 Gas Fuel Purge 6 0 Purge valves modularized into AM40 and AM10

Total 45 1

Only SSOV remains as GE Supplied GT Accessories Field Installed Valve



GE to EPC Piping Interface Points

MLI System 7F.03 7HA.01

0416 Lube and Lift Oil 9 8

0417 Cooling and Sealing Air 13 5

0420 Cooling Water 9 6

0422 Gas Fuel 4 4

0424 Liquid Fuel 4 1

0425 Atomizing Air 1 0

0426 Fire Protection 11 4

0442 Water Wash 13 8

0462 Water Injection 1 1

0471 Inlet and Exhaust 2 1

0477 Gas Fuel Purge 4 4

Total 71 42



Constructability Guide

A single document that compiles pertinent information relevant to a constructor and erector to estimate the scope of work necessary to install a GE 7HA gas turbine, generator, and associated ancillaries compared to the 7F.03.

constructability & maintainability seminar...drain piping compartment space heaters jack stand...

Documents