Project Engineering Department

1 Fuel System Technology

Off-Base Fuel Systems for Gas Turbines

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2 Fuel System Technology

Gas Turbine fuels and Fuel Flexibility

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3 Need for Fuel Flexibility Fuel System

- Fuel Availability - Cost of Fuel - National Interest

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Gas Turbine Fuels:

Gaseous Fuels: 1) Natural Gas 2) Refinery Gases (High Hydrogen content) 3) Liquified Petroleum Gas (LPG) [wet gases]

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Gas Turbine Fuels:

Liquid Fuels: 1) Distillates - Naphtha, Kerosene, Diesel Oils 2) Heavy Oils (ash forming)
- Petroleum Crude Oils, Petroleum Residual Oils

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Fuel Gas System:

1) On-Base fuel gas system
- to regulate gas fuel flow based
on load of gas turbine

2) Off-Base fuel gas system

- provides necessary fuel gas conditioning as required by on-base system

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On-Base Gas Fuel System requirements:

1) The fuel gases shall conform to spec. GT 10197, fuel gas supply specifications

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The fuel gas properties Which are controlled in off-base fuel gas system, as required by GT

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1) Removal of particulate matter

sand and clay - Rust - Construction debris

Particulate matter to be removed down to 10 microns

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2) Ensuring 28 Deg. C super heat of fuel gas at GT inlet - above hydrocarbon dew point - above moisture dew point thus ensuring no condensate will form in the GT on-base system 3) Prevention of hydrate formation in fuel gas treatment system 4) Maintaining fuel gas pressure within the allowable limits of gas turbine.

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Effect of contaminants on GT operation:

1) Particulates: - Plugging of nozzles - Erosion - Deposition

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Effect of contaminants On GT Operation:

2) Liquid condensates: - Rapid excursions in firing temperature and GT load - Melting of hot gas paths - Blow out (liquid water)

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Effect of contaminants On GT Operation:

3) Gas Hydrates are crystalline materials that are formed when free water is present in the gas which combines with gas compounds. Hydrates can plug stagnant areas like orifice plates, valves,instrumentation etc. Maintaining fuel gas above water Dew point temperature ensures prevention of hydrates formation.

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Main Processing equipment for Fuel Gas Conditioning:

1) 2) 3) 4) 5) 6) Dry Gas Scrubber Particulate filter Filter Separator Fuel gas heater (Electric/Steam) Pressure Control Station Fuel gas compressors (if fuel gas is available at a lower pressure than required by GT) 7) On-off valves, vent header, drain tanks etc.

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Various configurations of fuel gas conditioning systems Involving simple particulate filter to most complex systems are engineered to meet the specific requirements of a project.

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If a gas compressor is used, if incoming gas supply pressure is too low to meet the gas turbine pressure requirements, advantage can be taken of heat of compression to avoid the cost of a gas super heater. A surge vessel is required for on-line change over of GT to alternate fuel in case of tripping of fuel gas Compressor.

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Special Considerations for Refinery gases:

1) If Refinery gas contains more than 5% by volume of Hydrogen - alternate startup fuel is required - No flanged connections are permitted within GT Hall - GT requires inert gas purge/blocking system. Nitrogen shall be made available at two pressure s 2 Bar (g)

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Special Considerations for Refinery gases: (contd.)

and 30 Bar (g) for the purpose of purging.

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Fuel Oil System:

1) On-Base fuel oil system
- to regulate fuel oil flow based
on load of gas turbine

2) Off-Base fuel oil system

- provides necessary fuel oil conditioning as required by on-base system

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On-Base Fuel Oil System requirements:

1) The fuel oils shall conform to spec. GT 10505, Gas Turbine Liquid fuel specification.

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Fuel Oil Properties and Contaminants that affect the operation of GT and Fuel Handling System System requirements:

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Concerned fuel oil properties:

- specific gravity (separation of impurities) - viscosity (pumping, heating, atomization, lubrication) allowable max. limit 10 cst for Distilates 20 Cst for heavy oils (for proper atomization) Min. allowable viscosity is 1.8 Cst for proper lubrication. - flash point (explosion proofing requirement, floating roof requirement for tanks) - wax (plugging of filters)

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Concerned fuel oil contaminants:

- solids (sand, rust, metallic oxides which cause fouling of filters, control systems, fuel pumps, flow dividers, and fuel nozzles) - water (presence of water along with bacteria in oil will degrade oil creating slimy substance which can plug the filters and jam the flow divider)

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Concerned fuel oil contaminants: (contd.)

presence of water can create emulsions which will plug the filters. water can also cause corrosion if left in flow dividers and pumps. - Trace Metals (Na, K, Va, Ca, Lead) (hot-temperature corrosion, deposits)

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- Distillate fuel oils such as Naphtha and kerosene are generally pure fuels require only proper maintenance of storage tank and fine filtration. - Diesel fuels generally confirm to IS-1460 which has filterable dirt as high as 4 mg/100 ml, thus require a centrifuge to reduce the load on filtration equipment provided. - Ash forming fuels contain trace metal components in addition to impurities found in distillates in higher proportions, calling for fuel washing.

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- The minimum allowable viscosity for GT is 1.8 Cst. Viscosity of oil below 1.8 Cst requires dosing of additive Hitec-580. Normally Naphtha fuel oil requires above dosing. - Trace metal vanadium can not be removed by washing which requires dosing of an inhibitor. - Lead cannot be removed by any process. Hence, shall be limited in the fuel oil specification.

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Off-Base Liquid Fuel Handling Systems:

1) Fuel Oil Unloading System 2) Fuel Oil Storage System 3) Fuel Oil Treatment System 4) Fuel Oil Forwarding System 5) Fuel Oil Dosing System 6) Fuel Oil Filtration System 7) Fuel Oil Drain System

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Steps to ensure minimize chances of contaminated oil unloaded at site:

1) Cleaning the tank wagon before loading by supplier 2) Dedicated unloading tankers (or) trucks 3) Providing Coarse filter at unloading inlet of tank

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Recommendations on Fuel Oil Storage System:

1) Two Storage tanks are recommended for each fuel. One tank is in use. The other tank is settling. After filling a tank or after adding additional fuel to it, a minimum of 24 hours settling should occur before taking fuel from the tank. 2) Fixed roof tanks are preferred. For volatile fuels fixed cum floating roof tanks are to be provided to avoid ingress of rain water. 3) Water and other sediments should be drained on a regular basis.

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Such steps as draining water and sediment from the tank regularly, letting a tank settle for 24 hours before use and making sure that the drain is at the lowest point in the tank - All these can reduce problems related to fuel pump, flow divider and check valve and short filter life etc..

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