GT Inlet Air Cooling_March_2016

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Mott Macdonald Thailand

18/03/16

Gas Turbine Inlet Air Cooling (GTIAC)Optimize Efficiency & Maximize Power

2 Johnson Controls, Inc. — PUBLIC

Global multi-industrial company in industrial cooling,

energy storage, automotive and building industries

170,000Employees

150+Countries

$42.8 BillionRevenues in 2014


Industrial cooling and complex systems experts

• Worlds’ most established industrial cooling companies, each with more than 100 years of experience in their markets.

• Only industrial cooling manufacturer to provide a full line of cooling, compression and control products together with in-house system integration expertise.

• Portfolio of 2,000+ high-performance heating, cooling, refrigeration and controls products globally supported by unmatched ‘local’ customer service infrastructure.


Johnson Controls portfolio of GTIAC solutions

YORK® YD Chiller YORK® YK Chiller

YORK® CYK Chiller

Providing cooling to

optimize gas turbine

performance worldwide.

YORK® Absorption

Chiller

YCP-2020

First deployed in a

GTIAC application in

the US in 1980s.

Packaged solutions

and first containerized

system in market.


Fixed speed Gas Turbines are

fixed volume air flow machines

• Increases in ambient air

temperature reduce GT output

and fuel efficiency

• Performance recovery is possible

through cooling of the inlet air

• Cooling/augmentation technologies are in operation globally,

mainly;

• Evaporative fogging or wetted media systems

• Mechanical based systems (absorption & electric chiller based)

• Wet compression (proprietary OEM technology)

Gas Turbine Inlet Air Cooling


GenGAS

TurbineGen

GAS

Turbine

Gas Turbine Inlet Air Cooling Concept

Inlet Air Properties

15°C DB; RH 60%

Density: 1.22 kg/m3

Inlet Air Properties

45°C DB; RH 30%

Density: 1.098 kg/m3

Cold Weather Hot Weather

10%Mass Flow

Reduction

• Gas Turbines (GT) are constant volume machines.

• As the temperature of the air entering the compressor increases, the density of

the air decreases.

• Lower air density reduces the mass flow entering the GT and therefore

reduces the power output of the GT.


HEAT RATE > 105%

POWER OUTPUT <70%

45°C

15°C

Gas Turbine Inlet Air Cooling Concept

• Gas Turbine (GT) Heat Rate is also affected by the temperature, heat rate

increases when temperature increases.

• GTIAC technologies cool down the GT inlet air to recover the power output and

heat rate degraded by the temperature rise.

• Impact of GTIAC is similar to ambient temperature naturally going down.

Source: A novel concept for reducing

water usage and increasing efficiency

in power generation, 2004


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Temperature and Relative Humidity Variation (23/04/14 Bangkok Airport)

Temperature Relative humidity

DESIGN

Gas Turbine Inlet Air Cooling, Evaporative V’s Chilling


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-20Enthalpy (kJ/kg)-10

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Absolute humidity (kg/kg)

35°C28°C10°C

Design

Point

Cooling Point

Evaporative

Cooling Point

Chilling

Gas Turbine Inlet Air Cooling, Evaporative V’s ChillingOperation at Design Point 35C and 57% RH

• Evaporative ΔT ≈ 7°C

• Chilling ΔT ≈ 25°C


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Temperature and Relative Humidity Variation (23/04/14 Bangkok Airport)

Temperature Relative humidity

OFF-DESIGN

Gas Turbine Inlet Air Cooling, Evaporative V’s Chilling


10

20

30

405060708090100Relative humidity (%)

-20Enthalpy (kJ/kg)-10

0

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Absolute humidity (kg/kg)

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26.5°C10°C

Design

Point

Gas Turbine Inlet Air Cooling, Evaporative V’s ChillingOperation at Off-Design Point 29C and 80% RH

Cooling Point

Evaporative

Cooling Point

Chilling

• Evaporative ΔT ≈ 2.5°C

• Chilling ΔT ≈ 19°C


Gas Turbine Inlet Air Cooling, Chilling + Wet CompressionRolls Royce Trent 60 DLE

• Mechanical Chilling can be applied also when the Gas Turbine is

equipped with OEM Wet Compression system, e.i (Rolls Royce

Inter Spray Intercooler ISI or GE Sprint systems).

No Wet

Compression,

No Chilling


Gas Turbine Inlet Air Cooling, Chilling + Wet CompressionOperation at Design Point 35C and 57% RH

With Wet

Compression

With Wet

Compression

and Chilling


GTIAC System

Mechanical Absorption

HRSG

Thermal

Storage

Tank

Heat Rejection

Equipment

(Cooling Tower)

Gas Turbine

Transformer

Air Filter House

(Housing, Coil, Filter)

Chiller System


In many new built plants, complete GTIAC

system has not been considered holistically

during the design stage.

Cooling coils are supplied by GT OEM

Chillers are supplied by EPC

•

•

GTIAC specifications are often based on

HVAC standards or are “cut-paste” from older

sub optimal GTIAC system specifications.

Very high approach between chilled water

temperature and inlet air temperature (>10°C)

Chillers operating in standard HVAC conditions (

7°C / 12°C )

•

•

GTIAC System Optimization (Early Phase consideration)


GTIAC System for cooling 2 X 50MW GTs from 43°C (30%RH) to 18°C

Cooling Capacity: 12,300 kW (3,500 RT)

OPTIMIZED

DESIGN

BASE

DESIGN

Chilled Water Leaving Temperature:

Chilled Water Return Temperature:

Chilled Water Delta T:

3500 RT supply by two

Equal Centrifugal Chillers in

•

•

•

•

7°C

12°C

5°C

Parallel

configuration

11°C

24°C

13°C

Series

Counterflow

configuration



Series Counterflow Arrangement

• 2 Equal Chillers

• 1 Pass Evap. and Cond.

35 °CLCWT

31°C ECWT

7°C LChWT

12°C EChWT

Saturated

refrigerant

5°C (3.5 bar)

37°C (9.4

bar)

Water

temps

35 °C LCWT

31°C ECWT

7°C LChWT

12°C EChWT5°C (3.5 bar)

37°C (9.4

bar)

Parallel Arrangement;

• 2 Equal Chillers

• 2 Pass Evap. and Cond.

ECWTLCWT

EChWT LChWT

24°C 11°C

38°C 31°C

Evaporator

Condenser

40°C

15°C

34°C

OPTIMIZED DESIGNBASE DESIGN

Evaporator

Condenser

Evaporator

Condenser

Evaporator

Condenser

36°C

9°C

Water

temps

Water

tempsWater

temps

Saturated

refrigerantSaturated

refrigerant


17°C


BASE DESIGN

Evaporator 1Compressor 1

Condenser 1

Lift 1

5.1 bar

Compressor 2

Lift 2

5.2 bar

4.0 bar

9.1 bar

Compressor

Condenser

Pressure

Enthalpy

Lift

5.9 bar

9.4 bar

3.5 bar

OPTIMIZED DESIGN

Pressure

Enthalpy

Evaporator

Condenser 2 10.1 bar

Evaporator 2 4.9 bar



OPTIMIZED

DESIGN

BASE

DESIGN

Chiller electrical load:

COP =

*Chilled Water Head of 35m

*Cooling Water Head of 25m

*Wet Bulb Temperature of 28°C

-30%3,000 kW 2,100 kW

-27%2,300 kW

5.3

1,680 kW

7.3

250 kW*

2,120 m3/h

110 kW*

815 m3/h

225 kW*

3,080 m3/h

150 kW*

1,720 m3/h

225 kW* 160 kW*

-56%

-33%

-29%

CW Pumps Load:

Flow Rate =

ChW Pumps Load:

Flow Rate =

Total Parasitic Load:

CT Fans Load:



OPTIMIZED DESIGNBASE DESIGN

Cheaper cooling coils

Bigger chillers, pumps,

cooling tower

Bigger pipe sizes and line

components

Overall higher cost

More expensive cooling coils

(require more heat transfer

surface)

Smaller compressors, compressor

motor, pumps and cooling tower

Smaller pipes and valves

•

•

•

•

•

•

•

≈ 900 kW less parasitic load at

design conditions for plant lifetime

(20 ~ 25 years)



JCI integrates chiller package

systems optimised for the needs of

the power industry

• Bespoke packaging of the right

chillers for the application

• System performance optimised

• Packaged modules, pre build in a

controlled environment, reduced

site installing time and risk

Modular Packaged GTIAC Systems


April 2015

18m

9m

4.5m

Johnson Controls - Modular Chilled Water System Modular System Package 4,000 – 5,000 RT (14,000kWth - 17,500kWth)


Johnson Controls – YPS Modular Chilled Water System &

Cooling Tower

Chilled Water Modular System Package 16,700 kWth

Note: Cooling Tower Can be Located

Remote from Chiller System or Overhead

10m

10m

25m

24

1 2

4 3

Modular Chilled Water System – Site Delivery

25

5 6

8 7

Modular Chilled Water System – Site Delivery


GTIAC Modular System YCP-2020

Modularized chiller package system

optimized for the power sector:

compact, self-contained, flexible

• Std. container modules, minimize

site footprint and transport costs

• Factory built and tested in dedicated

JCI facility, controlled quality, fast

site erection

• System modules with auxiliaries, electrical system and controls, local and

DCS control capable

• Modularization systems target ~ 8,000kWth (~2,200RT) capacity

• Industry leading $/RT first cost

• Delivery Ex-works ~ 20 weeks


April 2015

Johnson Controls – YPS Modular Chilled Water SystemYork Modular YCP 2020 System Package ~2,200 RT

YCP2020

6.0m10.2m

2.6m


High Level Controller

CPO (10)

First Chiller Controller

2# OV1

Second Chiller Controller

1# OV1

Customer Controls

DCS

E-Link E-Link

Modbus RTU(STD)BACnet IP/BACnet MS/TP(OPTION)

CHW

Inlet

CHW

Outlet

T

E

2

T

E

3

T

E

1

Johnson Controls – YPS Modular Chilled Water SystemControls


2 x Chiller modules in SCF

1 x Auxiliaries module

Water-Cooled

MotorEvaporator

CompressorCondenserHGBP


System will be delivered in three 20’

shipping container sized modules

•

•

•

Factory assembled and tested at

dedicated JCI facility in Wuxi, China

Modules based on 20´ std shipping

container envelope

Removable access panels for

maintenance

•

•



Starter

Dry Area

CW Pump

CHW Pump

Moveable door for

Wet/dry area division

Starter and switchgear

Chilled and Cooling water pumps

Chiller Plant Optimization (CPA) control system panel

Auxiliary module incorporates

•

•

•

Segregated ‘Dry’ section with

controlled environment

Single LV power supply connection

to Aux module

Incorporated CPA control system

panel

•

•

•


Johnson Controls GTIAC Summary

• JCI is the only chiller OEM

packaging modular GTIAC systems

for the power industry

• Full GTIAC system design capability

for power plant duty and optimum

system performance & cost

• Over 100 years of Industrial Cooling

and over 20 years of global

experience in GTIAC applications

• Extensive chiller solution range

• Unrivalled service support in every

country we serve

• NYSE listed, US$ 40 Bn+ /year,

financially strong & stable

[email protected]

[email protected]

mailto:[email protected]

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