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2013

AJUMOGOBIA

IGONIKON TARIAH.INSTITUTE OF MANAGEMENT

AND TECHNOLOGY, ENUGU.

12/15/2013

NEW DESIGNED GAS FLARE STEAMTURBINE PLANT FOR POWERGENERATION.


2013

AJUMOGOBIA



12/15/2013



2013

AJUMOGOBIA



12/15/2013



DEDICATIONI ardently dedicate this project to the Almighty God for His absolutewisdom and knowledge in putting up an imagination into reality.


TABLE OF CONTENTSTitle

Dedication

Table of Contents

1. Introduction ------------------------------------------------------------ page 1

2. Project Statement ----------------------------------------------------- page 3

2.1 Steam Plant --------------------------------------------------------------page 3

2.2 Combustion Chamber ------------------------------------------------ page 7

2.3 Walls of the Steam Plant ---------------------------------------------page 12

2.4 Steam Turbine-----------------------------------------------------------page 15

3. Project Objectives------------------------------------------------------ page 19

4. Project Implementation---------------------------------------------- page 20

5. Project Monitoring---------------------------------------------------- page 21

6. Project Budget----------------------------------------------------------page 22

7. Conclusion---------------------------------------------------------------page 23

INTRODUCTION


This project is all about bringing sanity to our environment, by reducingthe negative effect of pollution to the Ozone Layer, and also creating aconducive environment for mankind by increasing the economicalgrowth/value of the nation.

The total process of achieving this project is of a low cost to becompared with the effect/disadvantages it causes to mankind and hisenvironment.

Gas Flare Stack at one of the dispatch station in USA.

It is rightly stated that health is life and wealth, so the aim of thisproject is to actualize the safety of our ozone layer which is health,


creating better living for mankind which is life, and increasing theeconomic standard of living in our society which is wealth.

The idea of this project is to convert the Oil and Gas flare

NNPC Flare stack in Port Harcourt

which stands as a pollution and negative output causing anuncompromised flux to our climate condition, mankind and itsenvironment into electricity.


Project StatementIn operation, we are converting the Oil and Gas Flare which has heatenergy, gaining 92% of the energy into steam to propel a steam turbinewhich power ranges from 1horsepower up to 1.5GW(Approximately2,000,000Hp).

The possibility of achieving steam energy is by conserving the loss heatenergy from the gas flare into an enclosed chamber having less heatloss of 8%. A boiler plant is set to run a steam turbine as in other cases,but in this process, we are designing a new brand system to generatethe steam energy called Steam Plant to run the turbine.

Steam PlantSteam plant generates high pressure steam by transferring the heat ofCombustion from the heat transfer sections. This part of the articleseries briefly describes the flow and arrangement of the heat transfersection in the steam plant. In line diagrams help make the conceptclear.


wat

erin

let

stea

mou

tlet

gas burner/cooker

water tank

An in line diagram of a Steam Plant.

1

2

3

4b

Gas inlet

Ignition

TransparentTempered Gas

Walls

Steam Plant showing both the gas inlet and the ignition.(Diagram 1)


steam outlet

1

2

3

4b

Steam Plant showing the steam outlet. (Diagram 2)

Assembly part of the Steam Plant (Diagram 1a)


2Assembly part of the Steam Plant (Diagram 1b)

3

Assembly part of the Steam Plant (Diagram 1c)


Combustion ChamberIt can also be called the interference chamber, the chamber were theheat energy from the burner at a higher temperature relate with water(H20) to form steam.

tempered glassgas inlet ignition

Side view of the combustion chamber showing both thegas inlet and the ignition. (Diagram i)


steam outlet

Side view of the combustion chamber showing the SteamOutlet. (Diagram ii)

The chamber is in cooperated with the following: Gas Burner/cooker Ignition Water tanks/panels.

Gas Burner/CookerThis section can also be called the burning section or the burner. Theburner serves as the outlet of the gas that produces flame. Is from theburner that the heat for converting water into steam is been generated.The burner comprises of both the gas and the ignition.


Gas Burner/Cooker

IgnitionIs a device or apparatus used for starting up the fire at the cooker, itdiffuse with the expel gas to produce fire which gives heat or producesheat energy.Water tanks/Panels.Volume of one unit mass of steam is thousand times that of water,when water is converted to steam in a closed vessel the pressure willincrease. Boiler uses this principle to produce high pressure steam.Conversion of Water to Steam evolves in three stages.

o Heating the water from cold condition to boiling point orsaturation temperature – sensible heat addition.

o Water boils at saturation temperature to produce steam - Latentheat. Addition.

o Heating steam from saturation temperature to highertemperature called Superheating to increase the power plantoutput and

o Efficiency.


2water inlet

steam outlet

Single Phase Water Tank.

The tanks are medium is sizes and cylindrical in shapes that functions asthe storage and feeding point for water and the collection point forwater and steam mixture. This is the most important pressure part inthe steam plant that gives rises to the pressurized steam after heated.Each of the tanks has two (2) major orifice (inlet and outlet). The inletallows the flow of water from an external feed tank outside the plantinto the chamber (internal tank), while the outlet gives way for thehighly pressurized steam to flow into the turbine for the rotation of theturbine blade, transmitting its rotational motion to the alternator forthe generating of electricity.


gas inlet

ignition

Water tanks/panels placed in parallel on the gas burner.

Feed Water PumpThe first step is to get a constant supply of water at high pressure intothe steam plant. Since the plant is always at a high pressure. ‘Steamplant feed water pump’ pumps the water at controlled pressure intothe water tank/panels’. The pump is akin to the heart in the humanbody.


Walls of the Steam PlantThe wall of the entire system is incorporated with both Thermal BarrierCoating (TBC) and Super Wool Fibre Mastics (SFM).

.

Thermal Barrier Coating (TBC) are highly advanced material systemsusually applied to metallic surfaces, such as gas turbine or aero-engineparts, operating at elevated temperatures, as a form of exhaust heatmanagement. These coatings serve to insulate components from largeand prolonged heat loads by utilizing thermally insulating materialswhich can sustain an appreciable temperature difference between theload-bearing alloys and the coating surface.[1] In doing so, thesecoatings can allow for higher operating temperatures while limiting thethermal exposure of structural components, extending part life byreducing oxidation and thermal fatigue. In conjunction with active film


cooling, TBCs permit working fluid temperatures higher than themelting point of the metal airfoil in some turbine applications. Inconjunction with active film cooling, TBCs permit working fluidtemperatures higher than the melting point of the metal airfoil in someturbine applications.

Structure

Thermal barrier coatings typically consist of four layers: the metalsubstrate, metallic bond coat, thermally grown oxide, and ceramictopcoat. The ceramic topcoat is typically composed of yttria-stabilizedzirconia (YSZ) which is desirable for having very low conductivity whileremaining stable at nominal operating temperatures typically seen inapplications. Recent advancements in finding an alternative for YSZceramic topcoat identified many novel ceramics (rare earth zirconates)having superior performance at temperatures above 1200 °C, howeverwith inferior fracture toughness compared to that of YSZ. This ceramiclayer creates the largest thermal gradient of the TBC and keeps thelower layers at a lower temperature than the surface.

TBCs fail through various degradation modes that include mechanicalrumpling of bond coat during thermal cyclic exposure, especially,coatings in aircraft engines; accelerated oxidation, hot corrosion,molten deposit degradation. There are issues with oxidation (areas ofthe TBC getting stripped off) of the TBC also, which reduces the life ofthe metal drastically, which leads to thermal fatigue.

The TBC can also be locally modified at the interface between thebondcoat and the thermally grown oxide so that it acts as athermographic phosphor, which allows for remote temperaturemeasurement.


Mastic

Morgan thermal Ceramics’ mastic products are used in hightemperature applications where patching and filling of voids isrequired. These products are available as pumpables (with pumps),moldables, air-setting cements, and coatings.

Superwool® Fibre mastic is a mouldable form of fibre which can betrowelled, hand moulded, or injected from a hand held pressure gun.Drying converts the Mastic into a strong, hard - yet light weight -insulating material which has great thermal stability up to its typicalcontinuous use temperature. Although air drying is possible, it isrecommended that assisted drying be carried out below 100°C (212°F).This product features excellent resistance to cracking and spalling andthe dried material has strong adhesive properties.

Our Superwool® Fibre mastic is a ready to use, highly insulatingmaterial with a homogenous structure.


The Steam Turbine

Working Principle of Steam TurbineThe working principle of steam turbine is very important to be knownin the power plant system. Steam turbine is the engine, where theenergy of working fluid is used directly to rotate the turbine blades. Inthe turbine, the working fluid undergoing a process of expansion,namely the pressure drop and flow continuously. The working fluid ofsteam turbine is steam. Steam turbine classification can be categorizedbased on steam flow direction, working principle, exit steam and steampressure.

In general, the steam turbine system consists of several components,such as: pumps, steam plant, combustion chamber, condenser andturbine. Turbine is much in use for power generation, aircraft, in theindustry, and others.

Steam turbine is one of machine types that use a method of externalcombustion engine. The heating of working fluid (steam) is doneoutside the system. In brief the working principle of steam turbine asfollows:

Steam enters into the turbine through a nozzle. In the nozzle, heatenergy from steam is converted into kinetic energy and the steamis expanding. Steam pressure at the exit of nozzle is smaller whencompared with at the time of enter into nozzle, but otherwise thevelocity of steam out from nozzle is greater than at the time ofenter into the nozzle.

The steam gushing out of the nozzle is directed to the turbineblades with arches shaped and fitted around the wheel turbines.Steam flowing through gaps between the turbine blades isdeflected towards following the curve of the turbine blades. The


changes in steam velocity raise the force that encourages andthen rotate the turbine wheel and shaft.

If the steam still has velocity when it leaves the turbine bladesmeans that only some of the kinetic energy of steam is taken bythe turbine blades which are running. More than one line of blademotion is installed to utilize the remaining kinetic energy whensteam leaves the turbine blades.

Before entering the second line of blade motion, so between thefirst row and second row blades motion is mounted one line fixedblade (blade guide) that allows you to change the direction of thesteam velocity, so steam can enter the second line of blademotion in the right direction.

The velocity of steam when it leaves the last blade motion shouldbe made as small as possible, so that the available kinetic energycan be utilized as much as possible. Thus the steam turbineefficiency is higher because of energy loss is relatively small.

Steam turbine plants generally have a history of achieving up to 95%availability and can operate for more than a year between shutdownsfor maintenance and inspection. Their unplanned or forced outagerates are typically less than 2% or less than one week per year.



Elliott steam turbine generator set with Elliott turbines, Model BYRH-UG, Serial Number B!002145-C 2, single stage back pressure style units.Engine, gearbox and generator are mounted in a common skid. tHe Elliott gearbox reduces the turbine speed of 5750RPM to a finalspeed of 1800RPM to drive a conventional 4-pole, 2-bearing alternatorrated 1000KW/1607KVA with 0.85PF,163AMPS and wound for2400/4160V/3/60HZ service.


PROJECT OBJECTIVES

The project is carried out with the following objectives:

1. To protect the Ozone Layer, environment and the living ofmankind.

2. To enhance the economic growth of the nation and as well thebetter living of human.

3. To enhance our transportation system.4. To enhance productivity of our industries.5. To enhance preservation.


Conclusion

The mean aim of this project is to actualize the safety of our OzoneLayer, preserving our climate condition for better living for mankindand its environment. This project if achieve will increase the economicstandard, employment and growth of the nation, and will also beautifyeach home with electricity.This project (steam plant) is low in cost construction, easy to maintainand can be manufactured locally here in Nigeria.