TurboPHASEModulePerformance
TestingPlan
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TurboPHASEModule
PerformanceTestingPlan
PowerPHASELLC
1061E.IndiantownRoad,Suite206
Jupiter,FL33477
www.powerphasellc.com
Preparedby Reviewedby Approvedby
SMA
SMA
SMA
TotalPages
5
Date
04/30/14
Revision
4
TurboPHASEModulePerformance
TestingPlan
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1. Summary
Thistestplanwillbeusedasreferenceforfield-testingoftheperformanceimprovements
atacombinedcyclepowerplantwithoneormoreTurboPHASEModules(TPMs).
2. TPMOverview
TheTPMconsistsofafourstageintercooledaircompressordrivenbyareciprocating
engineandaheat-recoverysystem.Thelatterisusedtocaptureexhaustheatfromthe
reciprocatingengineandraisethetemperatureofthecompressedairtomatchtheGT’s
compressordischargetemperaturebeforetheadditionalairisinjectedintothegasturbine
dischargechamber.
3. TestObjectives
TheobjectiveofthetestwillbeperformancecharacterizationoftheTPMsinstalledata
combinedcyclepowerplant.
PerformanceoftheTPMswillbeassessedbycalculatingtheparametersshownbelow.The
requiredmeasurementsnecessarytocalculatetheperformancearediscussedinsection3.
TPMPerformanceParameters:
· Incrementalpower(kW)
· Incrementalheatrate(BTU/kWhorkJ/kWh)
Priortothetest,itwillbedemonstratedthattheTPMsarecapableof:
· Automatedstart/stop
· Supplyingthegasturbinecompressordischarge-likeair
· Safeandreliableoperationofauxiliaryequipmentsuchasfuelandcoolingsystems
Duringthetest,itwillbedemonstratedthattheTPMsarecapableof:
· ForF-ClassUnits:Maintainingmanifoldpressureatleast230psig(~16bar)
minimumundermassflowrateofatleast10lb/s(~4.5kg/s)
· ForB/E-ClassUnits:Maintainingmanifoldpressureatleast190psig(~13.1bar)
minimumundermassflowrateofatleast10lb/s(~4.5kg/s)
· Changingautomaticallyfromfullinjectiontostandbymode,andbacktofull
injection
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TestingPlan
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Inaddition,itmustdemonstratethesafedisconnectionofthesystemfromthegasturbine
attheeventualoccurrenceof:
· Lowlubricatingoilsumptankliquidlevelorabnormaloiltemperature
· Coolingwaterovertemperature
· TPMEmergencyStopbuttonispressed
· Gasturbinetrip
4. GeneralTestGuidelines
4.1Measurements
AllcriticalTPMandplantinstrumentationmustbecalibratedwithinsixmonthspriorto
thestartoftesting.CalibrationsmustbetraceabletotheNationalInstituteofStandards
andTechnology.
4.2Maximumvariationonoperatingconditions
Thecalculatedvariationofdatashouldnotexceedvaluesgivenintable1.Testresults
obtainedoutsidethelimitswillnotbeaccepted.Anydeviationduringtestingwithinthese
limitswillbeinthefavorofPowerPHASEwhencalculatingtheresults.Thesedeviation
limitscanbemodifiedifagreeduponbybothparties.
Table1.Maximumvariationofplanttestconditions(adaptedfromASMEPTC22-2005)
priortoinjectiontesting
Variable
Poweroutput
Barometricpressure
Inletairtemperature
Fuelflow
Airinjection
Maximumdeviation
0.5MW
0.33%
1.3⁰F(0.7⁰C)
1.3%
0.2lb/s(0.1kg/s)
4.3ControlSettings
Allgasturbinecontrolsettingswillbeleftas-isduringthetestingunlessmodificationsare
agreeduponbybothparties.
4.4Testlog
Alogwillbemaintainedduringtestingtorecordthedifferentactionsandanyunusual
eventoroperationofthereciprocatingengine,gearbox,compressor,alliedequipment,or
combinedcycleplant.Annotationsshouldincludethetimeofoccurrenceandnameofthe
observer.Equipmentadjustments,andthereasonsfortheactionshouldberecordedas
well.
5. Performancecalculationmethod
Themainobjectiveofthistestistomeasuretheincrementalbaseloadperformance
improvementswiththeTPM(s).Grosspowerwillbemeasuredfromthegenerator
terminals.
=
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TestingPlan
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Energyinputiscalculatedastheproductofthemeasuredfuelmassflowrateandits
heatingvalue(onalowerheatingvaluebasis).Multiplefuelgassampleswillbetakento
determinetheheatingvalueofthefuelduringtesting.
= ̇
∗
Heatrateiscalculatedasthequotientbetweentheheatinputfromthefuelandthepower
output.Itmustbenotedthatattheinjectioncases,therearetwofuelinputs:onemeasured
atthecombinedcycleplant,andotherattheTPM(s).
+
=
TheincrementalpoweristhedifferencebetweenthegrosspoweroutputwhentheTPM(s)
injectair(Pinj)andthepoweroutputbeforeinjection(Pbase).Oncombinedcycleplantsthis
willincludeboththegasturbineandthesteamturbinegeneratoroutputs.
=
−
Notethatotheroperatingconditionssuchasductburners,evaporativecoolers,foggers,
chillersorinletbleedheatmustremainunchangedorturnedoffduringthetestingperiod
suchthatthebaselinepowerandheatrateremainsconstantduringthetest.
Finallytheincrementalheatrateiscalculatedasthequotientbetweentheincrementalfuel
andpower.NotealsothatQinjcorrespondstothefuelenergyinputwithairinjection,and
Qbasetothebase(noinjection)fuelenergyinput.
−
=
6. Testingoutline
6.1Preparation
Inpreparationforthetest,delegatesfromofthedemonstrationsiteandPowerPHASE
representativeswilldiscussthepresenttestingprotocol,coveringthefollowingitems:
· Agreementonsafetymeasuresandtestingprotocol
· Reviewtheplantinstrumentation,ensuringpropercalibration
· EnsurethatknowledgeabledelegatesfromtheutilitycompanyandPowerPHASE
willattendthetesting
· Logisticsandfuelhandling,inaccordancewithapplicableregulations
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TestingPlan
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6.2Testing
Previoustothetest,thecombinedcyclesystemmusthavebeeninrunningon
baseloadforatleastonehourtoensuresteadystateconditionsprevail.
Duringtestingallotherplantequipmentand/orauxiliariesthatcouldimpactthe
resultsshouldremainatsteadystateconditions.
Testingtimeswillbeatleast10minutestoavoidtransienterrors.Dependingon
thesiteconfiguration,longerperiodsoftestingtimemightberequiredtoensure
plantsteadystateconditionshavebeenmet.
WhenboththeutilityandPowerPHASErepresentativesagreethatthesteadystate
conditionshavebeenmetthefollowingeventswilloccur:
1. Isolationvalveopened
2. InjectionControlValve(ICV)openatarateof(rateagreedtobycustomerin
(lb/s)/minor(kg/s)/min)untilmaximuminjectionrateisaccomplished
Afteratleastthreesuccessfulrunsofthefullinjectiontest,additionalconditions
willbeevaluatedinaccordancewiththetestschedule.
TPMsshutdownandinsolationvalveclosed.
7. Testresultsandfollow-upactions
Aftertesting,testdatawillbereviewedtodetermineifanyofitshouldberejectedpriorto
calculatingtheperformanceresults.Testdatamayalsoberejectedinanomalouscases
suchaschangeinambientconditionsabovetheprescribedtestlimits,measurement
equipmentinconsistences,ormechanicalmalfunction.Ifadditionaltestingisrequiredit
willbescheduledifitcanbereasonablybeaccommodatedundertheplantoperating
scheduleandaftercorrectinganyequipmentanomalies.
Afterthetestdatahasbeenreviewedandapprovedbyallparties,performancecalculation
willbecarriedout,andareportwillbeissuedprovidingtheperformanceresults.The
reportwillincludesignificantnotesfromthetestlogs.