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Presentation Introduction Capability overview Company profile - - PowerPoint PPT Presentation

May 19, 2023 283 likes •1.08k views

Technical Presentation on Exhaust Systems Acoustical Components Dampers & EJs Presentation Introduction Capability overview Company profile Reference projects Technical presentation Case study on Retrofits

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Technical Presentation on

Exhaust Systems Acoustical Components Dampers & EJ’s

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Presentation

  • Introduction
  • Capability overview
  • Company profile
  • Reference projects
  • Technical presentation
  • Case study on Retrofits
  • General discussion
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Aarding Thermal Acoustics Introduction & Capabilities

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  • Well established company (started in 1960)
  • Offices in Netherlands, Singapore, USA, Canada,

Brazil, China, India

  • Active in the Power-Energy and Petrochemical market
  • Part of CECO Environmental Group (Traded on

NASDAQ, CECE, Annual Sales ~$250M)

  • Strong global presence
  • $50M annual sales worldwide
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  • Supply of custom designed turnkey systems

– Baseload systems – Start Stop systems

  • Service and Maintenance for existing Power Plants

– Both on mature as well as on advanced Advanced type systems

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Capabilities

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Strong Global Presence

  • World-wide installed references
  • lobal fabrication experience
  • Multi-language staff (over 9 languages)
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Some General References – New Systems

– F9FA Bypass Stack GE-SADESSA – F9F-05 Teststand Mobile Exhaust GE-Greenville – F7FA PP13 PP14 12 Bypass Diverter Systems SCECO SAUDI – TVA Paradise USA – Shaybah M-East – Los Guindos Latin America – Energia Del Valle Latin America – BLNG II Asia – Jazan M-East – Nuevo Pemex 3rd Train Latin America – Shuqaiq M-East – Bandirma II Asia – Syncrude USA – San Gabriel Latin America – Wildcat USA Over 300 BYPASS Diverter systems installed (small to the largest)

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General References - Retrofits

– Retrofits of ducts and section repairs BLNG BRUNEI – F9E Corby UK Plenum,ducts and silencers EON ESBI UK – F9E Inlet Duct upgrades & revamps AES Europe – Retrofit of Exhaust system Silencer duct section PCS Singapore – F9E Retrofit of Exhaust section including Diverter TNB Gelugor – Retrofit of Exhaust Plenum System SESB Labuan – Retrofit of Exhaust Duct & Plenum Section SUEZ Rayong – Retrofit of GT Testcel KLMAIRFRANCE KLM Schiphol – Retrofit of refinery based Exhaust LM2500 BP Lingen – Retrofit of Complete Exhaust System CEB Mauritius – Retrofit of Exhaust Plenum System Tampere Finland – Retrofit of Exhaust Plenum System Shell Moerdijk – Retrofit of Exhaust & Silencer System PTT Ratchaburi – V94.2 Retrofit of Exhaust & Silencer System POWERTEK Bangladesh – Large number of Vent silencers mainly US, EU and Asia

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In-House Engineering Capabilities

– Experienced engineers

  • Industry related expertise
  • Full range of reference projects

– Advanced Engineering Techniques

  • Thermal Analysis
  • CFD analysis
  • Acoustic modelling
  • Metallurgical testing
  • HI CAD 3D design

Focus on Exhaust & Acoustical systems

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  • In House Design & Engineering

– All systems designed to order

  • Worldwide Manufacturing

– Production facilities in Europe, North America, Middle East & Asia

  • Site / installation supervision

Project driven Engineering Solutions

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  • EPC contractors,
  • OEM: Turbine & HRSG suppliers
  • Maintenance companies
  • End Users

World-Wide supplier to

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World-Wide supplier to EPC contractors, turbine & HRSG suppliers and Engineering companies.

  • Ref. i.e.:
  • GE
  • Alstom
  • Siemens / Westinghouse
  • Nooter Erikson
  • Shell-BLNG
  • Suez-Glow Energy
  • NEM
  • CMI
  • MHI
  • Doosan
  • Thosiba
  • Deltak
  • Cerrey
  • Metka
  • Vogt
  • Marubeni
  • Toyo /IKPT
  • Sedae
  • BP
  • PTT Thai
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Gas Turbine Exhaust Systems

Gas Turbi bine e Combin ined d Cycle le System tem Gas Turbi bine e Simple ple Cycle le System tem

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Capabilities

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Capabilities include;

  • Diverter Dampers (Toggle, Pivot, Louver)
  • Guillotine Dampers/Blanking Plates
  • Stack Dampers / Louver Dampers
  • Turbine and Exhaust Expansion Joints
  • Installation and commissioning supervision
  • Turnkey projects including erection
  • Service, maintenance and retrofit for existing

power plants

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Capabilities Bypass Stack – Simple Cycle

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Capabilities Bypass Stack – Combined Cycle

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Capabilities Bypass Stack – Combined Cycle

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Capabilities Bypass Stack – Combined Cycle

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Capabilities Bypass Retrofit in Malaysia Plenum, Ducting & Diverter System

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In Inte terna rnally lly In Insul ulate ated d Duc uctw twork

  • rk
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Capabilities Internal Insulation

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Capabilities (COLD CASING) Internal Insulation System

The Internal insulation system consisting of:

  • Outer casing of carbon steel (stiffenned)
  • Sheeting + flat washers AISI 409/321 materials
  • Studs + Nuts AISI 409/321,
  • Bio Soluble insulation wool 64/128 kg/m3 in 50 mm layers,
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Capabilities – Inlet Ducts

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Capabilities – HRSG

Insulation Systems

  • Top and Bottom Sections
  • Sidewall Sections

Internals

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La Large ge Dia iame meter ter Sta tack ck Dam ampe pers rs

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La Large ge tu turbi bine ne ex expa pans nsion ion jo join ints ts

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Capabilities Flue Gas Silencers

  • Noise reduction after a gas turbine.
  • Installed in Stacks or ductwork
  • Proven Acoustical Design – EU Patented
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Capabilities

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Capabilities Fluegas Silencers

European Patented Design Silencer Assemblies

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Flue Gas Silencers

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Flue Gas Silencers

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Capabilities Flue Gas Silencers / Baffles

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  • Noise reduction in steam and gas

applications

  • Proven Acoustical Design
  • Compact Design

– Reduced weight – Limited installation space required

Capabilities Vent Silencers

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Capabilities Vent Silencers

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Vent Silencers

  • General
  • Silencer type
  • Diffusers
  • Connections
  • Additional Features
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Vent Silencers – Silencer type

Inline Silencers Vent Silencers

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Vent Silencers - General

Design acc.:

  • ASME B31.1/3
  • PED (European projects, if

required)

Production Vent Silencers in:

– Malaysia – The Netherlands – Romania – Russia – USA

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Commissioning Silencers

  • Noise reduction during a commissioning /

steam blow-down type application

  • Designed for a rugged type service
  • Inlet components designed to withstand

pressure loading, debris impact and free water impact.

  • Rental Silencer
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Commissioning Silencers

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Commissioning Silencers

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Gas Turbine Exhaust Systems Ageing & Upgrades

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Ageing Operational Damages

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Gas Turbine Exhaust Ducts Major Drivers of Operational Damages

  • Ageing

– Wear & Tear of Exhaust & Silencer Systems – Multiple repair area’s weakening the Exhaust Structure – Alloy Degradation

  • Safety requirements

– Ageing systems showing excessive temperatures – unplanned maintenance events (casing cracks/ruptures etc)

  • Change in Power Plant Operation

– Market Driven two-shifting / Start Stops increase – Higher Temperatures & flue gas velocities in the GT exhaust ducting. – Minor defects in the external / internal insulation of exhaust ducts system rapidly leading to widespread damage (potential for significant loss of plant availability).

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Operational damages GE Gas Turbine Exhaust Plenum

Severe damage to the casing. Hot spots Un-reliable and Un-Safe operation

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Consequential Damages as a result

  • f elevated

temperatures on Bellows and transition / silencer ducts

Operational damages GE Gas Turbine Ducts & Bellows

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Deferred maintenance resulting in severe exhaust system damages as well as GT damage Operational damages GE Gas Turbine Units

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Fire hazards as a result of overheated turbine compartments

Operational damages GE Gas Turbine GT plenum duct GT side and Flex plate system

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Severe damage to the sheeting and insulation. Operational damages GE Gas Turbine Ducts – Insulation system

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Thermal Shock

Severe cracking and degradation

  • f original duct sections

Operational damages GE Gas Turbine Ducts

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Repair by welding Or Section replacement Does not offer a Lasting solution On Ageing and

  • lder design Type

Exhaust Systems

Operational damages GE Gas Turbine Ducts – Patch repairs

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Silencer Support failures Sections damaged

Operational damages GE Gas Turbine Ducts Flue Gas Silencers

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Upgrades & Life Extension

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  • Reduction of annual costs

– Lower annual maintenance costs – Increased Unit availability

  • Thermal improvement

– Different options to reduce temperature levels and required ventilation

  • Safety

– Lower (duct surface/bellow) temperatures – Lower Load chamber temperatures / better accesability

Upgrades ; Objectives

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  • Definition of system Requirements, Inspection & Analysis
  • Upgrade of silencer systems

– Supporting Cyclic Power Plant Operation or Life extension – Elimination of thermal shock for the silencer supports

  • Upgrade of ducting systems

– utilising only internal insulation ( current status “cold casing design” ) – Improved alloy structures adapted to higher EGT & gasflow – long term internal insulation integrity – safer operating regime – significantly reduced maintenance down time.

  • Upgrade of transition areas such as bellow systems

– Temperature reductions in critical access area’s (E.G. Load Chamber)

Upgrades to current industry standards

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Thermographic periodical inspections

Upgrades : Monitoring & Inspections

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Examples of Analysis & Flow Modelling

Flow Modeling Stress Calculations Silencer Support Stress Calculation Casing Stress Calculations Fluegas Silencers

Upgrades: Defining Solutions

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Example of dedicated silencer support design

Upgrades : Defining Solutions

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Example of upgraded Duct Design

Upgrades : Defining Solutions

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Example of ATA upgraded flex plate insulation kit FIK HTXA ™ temperature reduction at Plenum Duct Flex Plates

Bellow design installed Upgrades : Defining Solutions

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GE type Retrofit of Exhaust Duct, Silencer assembly & Plenum Duct

Case Study in Photographs Report from a Recent Project

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Retrofit Plenum Duct – Existing Degraded Flanges Plenum Duct Degraded & Distorted Old Design Plenum Duct Old design Box Type

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Retrofit Plenum Duct – Manufacturing Half Moon Sections COLD Upgraded Design Duct Sectional Design to accommodate fast installation during Overhaul

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Retrofit Plenum Duct – Manufacturing Half Moon Sections COLD Upgraded Design Duct

Sectional Design to accommodate fast installation during Overhaul

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Retrofit Plenum Duct – New Inner (GT) Side COLD Upgraded Design Duct Installation Outer (GT) Side COLD Upgraded Design Duct

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Retrofit Silencer Duct – New Silencer duct Including support structure

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Retrofit Silencer Duct – New

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Retrofit of Exhaust Duct, Silencer assembly & Plenum Duct

Exhaust Duct, Silencer Assy & Plenum Duct Custom Designed based upon

  • GT Gasflow & EGT
  • Duct Surface Temperature Requirements
  • Noise Abatement Requirements
  • Actual Plant Layout
  • Overhaul time & planning
  • Expected Exhaust System Life Extension
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Retrofit Exhaust Duct : Existing Bulging duct casing Degraded and damaged Carbon Steel Inner Duct Leaking Bellows

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Retrofit Exhaust Duct : Section Manufacturing

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Retrofit Exhaust Duct : New Custom Designed Access Door COLD Upgraded Design Duct New Bellow System

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Retrofit Silencer System - Existing Detached Silencer units Damaged Supports Damaged perforated sheets & depleted Insulation

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Retrofit Silencer System – Final Inspection Patented Design accommodating Cold Casing structure

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Retrofit Silencer System - New Silencer Assembly installed in Upgraded Cold Design Duct Upgraded Design Supports

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If you need support for the upgrade of your Exhaust System please contact us at; www.aarding.com