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Combined Cycle Power Plants

Operation, Maintenance and Planned Optimization

Organized by CLARION Technical Conferences in association with The Boyce Consultancy

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HOUSTON · JANUARY 16-19, 2007

COURSE PROGRAM

DAY 1

OVERVIEW OF THE MAJOR PLANT EQUIPMENT

This overview consists of all the major pieces of Equipment in the Power Plant from a mechanical and Performance point of view. An overview and survey of the TurboMachinery (Gas Turbines, Steam Turbines, and Boiler Feed Water Pumps), covering both mechanical and performance aspects are discussed. The selection and major characteristics of the rest of the plant equipment such as the Heat Recovery and Steam Generating (HRSG) systems, the Feed Water Heaters, and the Condensers are also included. The selection of the equipment, the plant layout, environmental considerations, and arrangement, including general mechanical and aerothermal characteristics of all plant equipment are discussed in detail. Various ASME, API, and other Codes covering all the major equipment will be discussed. An emphasis is placed on specifying and designing for maximum reliability. Cycle Analysis of the Combined Cycle Power Plant will be undertaken and optimization of the cycle based on the performance of the various components will be studied.

his four-day course deals with the design and general operation and maintenance characteristics of a combined cycle power plant with emphasis on the major plant Components, and the performance of the plant. Overall design and operation concepts along with basic operation and maintenance problems for the various pieces of TurboMachinery (Gas Turbines, Steam Turbines, and Boiler Feed Water Pumps) are discussed. Discussions and design parameters of the Heat Recovery and Steam Generating (HRSG) systems the feed water heaters and the Condensers are also included. Other topics covered are bearings and seals, lubrication systems, instrumentation, vibration analysis, flexible couplings aero-thermal performance and on-line condition monitoring of the Power Plant. An emphasis is placed on providing practical information with minimal theory.

WHO SHOULD ATTEND BENEFITS OF ATTENDING

· Improved job performance and decision making capabilities where power plant operations are involved. · Integrated understanding of practical power plant machinery, design, operation, and maintenance requirements. · Unbiased technology transfer between participants.

This course is aimed at engineers and operational personnel who need a broadbased introduction to practical operation and design considerations of a major combined cycle Power Plant. Participants are encouraged throughout the course to be engaged in active discussions so as to maximize their experience from the instructor and other participants.

INSTRUCTOR: DR. MEHERWAN P. BOYCE, P.E.

DR. MEHERWAN P. BOYCE, P.E., Ph.D., Fellow ASME & IDGTE; has 46 years of experience in the field of TurboMachinery in both industry and academia. His industrial experience covers 20 years as Chairman and CEO of Boyce Engineering International, and five years as a designer of compressors and turbines for gas turbines for various gas turbine manufacturers. His academic experience covers a 15 year period, which includes the position of Professor of Mechanical Engineering at Texas A&M University and Founder of the TurboMachinery Laboratories and The TurboMachinery Symposium, which is now in its 35th year. He is the author of several books, including the Gas Turbine Engineering Handbook (Elsevier), Cogeneration & Combined Cycle Power Plants (ASME Press), and Centrifugal Compressors, A Basic Guide (PennWell Books). He is a contributor to several Handbooks; his latest contribution is to the Perry's Chemical Engineering Handbook Seventh Edition (McGraw Hill) in the areas of Transport and Storage of Fluids, and Gas Turbines. Dr. Boyce has taught over 100 short courses globally attended by over 3000 students representing over 400 Companies. The pioneer of On-Line Condition-Based Performance Monitoring, Dr. Boyce has developed models for various types of power plants and petrochemical complexes, on- and offshore. His programs are being used in these types of facilities all over the world. Dr. Boyce is Vice Chairman of the Plant Engineering & Maintenance Division of ASME, and Vice chairman of the Electric Utilities Committee of the of ASME's International Gas Turbine Institute. The Boyce Consultancy is a diversified engineering consulting group dedicated to technical excellence in the field of turbomachinery. Its professionals are involved with the design, troubleshooting, and maintenance for manufacturers and users of turbomachinery. Specialized courses in various areas of design, operation and maintenance are offered to meet the specific needs of the turbomachinery community. The Boyce Consultancy engineers bring their substantial background in turbine engine design, performance evaluation, and field trouble shooting into the classroom, thus offering a unique blend of practice and theory in their courses.

DAY 2 Major Equipment

ADVANCED GAS TURBINE TECHNOLOGY

In this section, various types and sizes of gas turbines used in the petrochemical industry are discussed, along with their classifications by size and application. Comparison is made between industrial and aircraft derivative type of gas turbines. Methods of increasing cycle efficiency and the output power are also discussed. An overview of fuels and materials considerations will be made.

State of the art developments in gas turbine technology will also be reviewed. High temperature turbines, closed cycles and other developments are covered.

HRSG TECHNOLOGY

The study of the HRSG will be undertaken in conjunction with the Feed Water Heaters, Dearators, and Economizers, Plus the Preheaters, Evaporators, and Superheaters of each stage. A study of the Temperature distribution as a function of the Heat input is also studied with various optimization techniques to assure maximum effectiveness of the HRSG.

turbine is dependent on the pressure, temperature, and flow generated in the heat recovery steam generator. Performance analysis is not only extremely important in determining overall performance of the cycle but in also determining life cycle considerations of various critical hot section components. Techniques of determining the life of these components will be discussed

AXIAL FLOW COMPRESSORS AND TURBINES

Key aerothermodynamic considerations are covered including cycle analysis of gas turbines and centrifugal compressors. Gas turbine performance calculations will also be covered. This section also covers mechanical, performance and aerodynamic aspects of gas turbines. Radial inflow turbines are also discussed. Practical aspects related to gas turbines is emphasized in the discussion.

CONDENSERS

A study of the Condensers and the computation of the degree of fouling will be examined. The study will include techniques of computing the fouling in the tubes and the quality of the steam entering the unit. The effect of the fouling on the condenser pressure and the effect of that pressure on the entire Power output of the plant. Feed Water Pumps The design characteristic of the feed water pumps will be undertaken. Most of these pumps have centrifugal impellers and so a study of the flow in these impellers will be conducted and the performance characteristics of these pumps will be studied.

MAINTENANCE

Maintenance Cycles of the Gas Turbine, and other components of the Combined Cycle Power Plant are discussed. Maintenance techniques using borescope and spectrum analysis, including acoustic monitoring are discussed. Techniques for checking and conducting repairs on impellers, diffusers, bearings and foundation repairs are emphasized.

COMBUSTORS, MATERIALS COATINGS AND FUELS

A description of combustor types, chamber design, fuel atomization, ignition and combustor arrangements are presented. Metallurgical aspects of gas turbine blading, turbine wheel alloys, future materials and gas turbine coatings are discussed. The stress-time behavior of materials is also covered. Common failure modes and cases are presented. Sulphidation properties, specifications, fuel treatments, and heavy fuel operation is discussed. Coatings as applied to both the Hot Section Components and the Compressor will be discussed from both a life and performance point of view.

CASE HISTORIES

Case histories of various types of failures encountered in a Combined Cycle Power Plant are discussed. Participants are encouraged to submit their own failures and other problems so that these may be further analyzed. Participants are encouraged to participate in discussions.

On completing the course, participants will be eligible to receive 2.2 CEUs

CONTINUING EDUCATION

FUELS

Discussion on various types of fuels will be conducted from Natural Gas to Heavy Fuel Oil to Low Btu Gas. The behavior of the Gas Turbines on these different fuels will be studied as to their effect on gas turbine performance including the effect on gas turbine compressor surge and on the Heat recovery unit as well as on duct burners if used in the system.

DAY 4

POWER PLANT PERFORMANCE AND OPTIMIZATION

The study will include the computation of the deterioration of the various components, of a Combined Cycle Power Plant.. Performance computations will be as per various ASME PTC Codes. The performance analysis of a combined cycle is complex. Most new combined cycle plants operate at very high turbine firing temperatures. Thus variation in this firing temperature significantly affects the performance and life of the components in the hot section of the turbine. The compressor pressure ratio is high which leads to a very narrow operation margin, thus making the turbine very susceptible to compressor fouling. The performance of the combined cycle is also dependent on the HRSG and the steam turbine performance. The steam

The course material includes the textbooks The Handbook for Cogeneration and Combined Cycle Power Plants and The Gas Turbine Engineering Handbook by Dr. Meherwan P. Boyce, P.E.

COURSE MATERIALS

Day 3

STEAM TURBINE TECHNOLOGY

The design of the Steam Turbines will be undertaken in this section. The design of the High Pressure Turbine, which is usually an impulse turbine, will be discussed and the IP and LP turbines, which are usually reaction turbines, will also be studied separately

COURSE REGISTRATION FORM

COURSE FEE The Combined Cycle Power Plants Course - $2,400 Fee includes all course materials plus lunch and morning and afternoon refreshments each day. ADDITIONAL DISCOUNTS (check as appropriate) Simultaneous multiple registrations from the same company $100 discount per person Early Registration (registrations received prior to January 3, 2007 $100 discount (in addition to discounts above) TOTAL $_________________ PAYMENT OPTIONS I will mail a check, payable to CLARION Technical Conferences Bank transfer: Call: +1 713-521-5929 · FAX: +1 713-521-9255 · Email: [email protected] Send me an invoice. If you require a Purchase Order, please call +1 713-521-5929 or fax to +1 713-521-9255. Call us (+1 713-521-5929) Your order will be processed when we receive your call. Credit Card: Visa MasterCard American Express Diner's Club For fastest registration, register online now at www.clarion.org (secure server) OR, fax or mail this form to:

CLARION Technical Conferences 3401 Louisiana Street Suite 255, Houston, TX 77002. FAX (713) 521- 9255 TEL. (713) 521-5929

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InterContinental Houston Hotel 2222 West Loop South Houston, TX 77027, USA Tel: +1 713 627 7600 Fax: +1 713 961 3327 E-mail: [email protected] Don't forget to request Group Code X85 - to take advantage of the special rate (limited availability).

ACCOMMODATION

Cancellations made in writing and received on or before 10 business days prior to the event will be refunded less a $100 handling fee. Cancellations received after 10 business days prior to the event will not be refunded, and the full invoice fee will be payable regardless of whether you attend the event or not. Substitutions may be made at any time. Confirmation will be made in writing as soon as possible upon receipt of payment. This confirmation will be sent to the address given on the registration form, unless otherwise required. The organizers reserve the right to cancel any event due to insufficient enrollment. In this event fees will be refunded in full. However, the organizers assume no liability for travel or any expenses other than

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REGISTER ONLINE AT THE COURSE WEBSITE · WWW.CLARION.ORG

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