TEHNICAL REPORT

Humid Air Injection

Power Augmentation of Combustion Turbines

By: Russell W. Blades

Vice President

11757 Katy Freeway, Suite 1300 Houston, TX, 77079 Tel: 281-854-2164 www.hillenergysystems.com

Humid Air Injection Power Augmentation for Combustion Turbines

Introduction
The performance of a gas turbine is greatly affected by altitude, ambient temperature, mass flow, and inlet pressure to the air compressor and exhaust pressure from the turbine.

Gas turbine ratings are usually given at standard conditions defined by the International Organization for Standardization (ISO): 59F, 60% Rh and at sea level. However, when a gas turbine is not operating at these ISO conditions, its performance will differ from its nameplate rating. Manufacturers typically provide performance curves for their combustion turbines (CT), which show how ambient air conditions affect such performance factors as power output and heat rates. Figure 1 shows a performance curve for a Solar Mars 100 CT operating at various temperatures. While the ISO rating on this CT is about 10.7 MW (15,000 hp) with a heat rate of 10,520 Btu/kWh, at 90F (when electricity demand typically peaks and power is expensive), the power output from the Mars 100 decreases to 9.5 MW (13,000 hp) and the heat rate increases 10,805 Btu/kWh. Figure 1: Typical Combustion Turbine Performance Curves (Power Output & Heat Rate vs. Temperature)

Therefore, whether you are a Utility, IPP, Merchant, Industrial Site or Compressor Station, this loss in performance has a tremendous impact on your bottom line. Prudent owners, engineers and operators of these frame, industrial, heavy duty or aeroderivative combustion turbines must look at new ways of improving the performance of these assets in order to remain competitive in todays markets and to maximize shareholder value.

Humid Air Injection Power Augmentation for Combustion Turbines

Air Injection Power Augmentation

Air Injection power augmentation is quickly becoming the technology of choice in terms of performance improvements, magnitude of the power enhancement, return on investment, simplicity of operation, dispatch ability and NOx reduction. Air augmentation works by introducing an external supply of preheated and pressurized air into the gas turbine upstream of the combustor (i.e. after the compression cycle) to increase the mass flow to the turbine. The incremental power from air injection is proportional to the mass of the injected flow (see Thermodynamics of Power Augmentation section). Since the mass flow is added at the high pressure point of the cycle, the work of the gas turbines axial flow compressor is virtually unchanged (unlike other power augmentation technologies). The air can be either humidified (HAI) or dry (DAI). Humidification provides greater power augmentation, reduces the amount of supplementary air needed to increase the gas turbine total flow, saving on compressor work otherwise needed to pressurize a higher flow. It is important to note that unlike many other power augmentation technologies, the water for the HAI humidification process does not ave to be demineralized. In addition, HAI also reduces the NOx levels of the turbine Dry Air Injection still provides significant power improvements and is the preferred technology when water is scarce, non existent or expensive (such as pipeline compressor stations). In addition, if the air is not heated (remove HRU), then there will be some reduction of NOx, but at the expense of an increased heat rate. The simplified schematic of a humidified air injection plant is shown in Figure 2. Major components include standard off the shelf components such as a compressor train, a once through partial steam generator, a steam/water separator vessel, mixer, dearator, superheater and balance of plant equipment such as interconnecting piping, pumps, valves and controls. By using an off the shelf strategy with sound engineering and construction practices, the capital cost of a typical Humid Air Injection system is in the $200 - $250/kW range. Figure 2: Humid Air Injection Schematic

Humid Air Injection Power Augmentation for Combustion Turbines

The simplified explanation for gas turbine hot day loss is that inlet air losses density, thereby reducing mass flow and ultimately power output. In effect, with Humid Air Injection, gas turbines now operate throughout the year (even during the summer) as if the ambient air temperature was less than 40F (4C). Table 1 demonstrates this unique relationship and benefits for a simple cycle GE7FA gas turbine with a 3% H2O injection rate: Ambient Temperature 95F / 35C (summer) 80F / 27C 70F / 21C 59F / 15C 50F / 10C 40F / 4C (winter) GE7FA Net Power (MW) 147 158 165 171 175 178 GE7FA + HAI (MW) 177 184 184 184 184 185 Improvement (MW) 30 26 19 13 9 7

A comparison in performance curves for a GE7FA with and without HAI is shown below in Figure 3. Figure 3: Performance Curves for a GE7FA Combustion Turbine

While the ISO rating on this gas turbine is about 170,750 kW, when the ambient air conditions are 95F in the summer, this unit can only produce about 147,450 kW (i.e. 86% of nameplate). Unfortunately, this loss in performance occurs when the prices for electricity are at their highest and electrical demand is at its peak. With HAI (3% H 2O) technology, this power plant could now produce 177,000 kW/unit when the ambient temperatures are at 95F. Increasing the injection rate to 5% H 2O, would enhance the net power output would to 183,690 kWh/unit or a gain of 36 MW. Based on $100/MWh during peak periods and a power plant with three (3) GE7FA units, this improvement in power output (i.e. 30 MW/turbine) for a HAI system with a 3% H20 injection rate would be worth $9,000/hr to a plant operator.

Humid Air Injection Power Augmentation for Combustion Turbines

The Competition
The ambient effect curve (see Figure 1) clearly shows that turbine output and heat rate is improved as compressor inlet temperature decreases. Lowering the compressor inlet temperature can be accomplished by installing an inlet chiller, a fogging system, wet compression or an evaporative cooler in the inlet ducting downstream of the inlet filters. Careful application of these systems is necessary, as condensation or carryover of water can intensify compressor fouling and degrade performance. In fact GE has recently published a Technical Information Letter (TIL 1389-1R1) to inform F Class gas turbine users to cease inlet fogger, evaporative coolers and wet compression and perform blade erosion inspection (i.e. row 0 blade distress due to erosion). Field data collected by GE has shown significant erosion on most units operating inlet foggers regardless of the manufacturer. Other problems cited have been duct corrosion. In addition, treated water (demineralized) is required for fogging, wet compression and evaporative cooling.The cost of these modifications and operating issues must be included in any financial analysis of these technologies. The biggest gains from evaporative cooling, wet compression and fogging are realized in hot, low humidity climates. Evaporative cooling and fogging are limited by ambient wet bulb temperatures and inlet dry bulb temperatures of 50F (10C) and above because of the potential for icing of the compressor. For technologies like wet compression, the overspray of water also increases mass flow through the engine. Although this ultimately increases the output of the gas turbine, it also increases the power requirements of the compressor (i.e. due to where in the cycle the moisture is added). Unlike evaporative coolers, the ambient wet bulb temperature does not limit chillers in the same way. A refrigeration plant is used to maintain the inlet air temperature at around 50F (10C). However, the electrical power required to operate the refrigeration compressors, pumps and fans must be subtracted from any power improvements. Whereas the above technologies reduce temperatures or increase mass flow at the compressor inlet, steam and water injection technologies inject water or steam into the head end of the combustor or compressor discharge casing, which increases mass flow, reduces NOx and improves power output. Most gas turbines are designed to allow up to 5% of the compressor airflow for steam injection to the combustor and compressor discharge. However, it is important to understand that steam injection is expensive, can cut the life of hot gas path parts in half and can create localized thermal spikes and significant pressure oscillation in the combustors if not properly controlled. Table 1 clearly shows that Humid Air Injection offers the greatest amount of performance improvement at costs that are competitive with other methods on a simple dollar per kW basis: Table 1: Power Augmentation Technology Comparison Method Inlet Fogging Evaporative Cooling Wet Compression Conventional Steam Injection Inlet Chilling - Refrigeration Humid Air Injection Dry Air Injection Capacity + 5% to + 15% + 5% to + 15% +10% to +20% +10% to +15% +20% to +25% +20% to +30% +15% to +25% Heat Rate -2.5% -2.5% -1.5% -5% to 7% -5% -8% to 15% Injection temperature dependent NOx Reduction 5% to 10% None 10% to 20% 30% to 60% None 60% to 80% Injection temperature dependent $ per kW $50 - $100 $50 - $100 $200 $200 - $400 $200 - $400 $200 - $250 $250 -$300

Humid Air Injection Power Augmentation for Combustion Turbines

Thermodynamics of Power Augmentation

We touched earlier on the impact that ambient te mperature and mass flow has on the power output performance of a combustion turbine. Now lets look at power augmentation from more of an engineering standpoint. Temperature, altitude and even humidity all affect air density and its the air density that really affects the mass flow of the combustion turbine (refer to standard psychometric chart). For example, Table 1 shows the density (lbs/1000 ft3) of air at various temperatures and altitudes. Therefore, for a gas turbine with a compressor design flow rate of 100,000 cfm at sea level: At 40F, mass flow = 100,000 ft3/min x 79.04 lbs/1000 ft3 = 7,904 lbs/min At 90F, mass flow = 100,000 ft3/min x 72.20 lbs/1000 ft3 = 7,202 lbs/min This change in mass flow will have a direct impact on the power output of the combustion turbine, as we shall see shortly. Table 1: Air Density (lbs/1000 ft3) at Various Temperatures and Altitudes

Temp, F 40 50 60 70 80 90 100

0 ft 79.04 77.52 76.00 74.48 72.96 72.20 70.68

1000 ft 76.00 74.48 73.72 72.20 70.68 69.92 68.40

2000 ft 73.72 72.20 71.44 69.92 68.40 66.88 65.36

3000 ft 70.68 68.40 67.64 66.88 65.36 64.60 63.08

4000 ft 67.64 66.88 66.12 64.60 63.08 62.93 60.80

5000 ft 66.12 64.60 63.84 62.32 60.80 60.04 58.52

You may recall from a simple cycle (Brayton) analysis of a gas turbine, the following relationships: 1. 2. 3. Pt = m x cp x (T 3 T 4) Pc = m x cp x (T1 T 2) Pn = Pt - Pc

Electricity or Mechanical Work Out

Gas Turbine Brayton Cycle

Temperature Entropy Diagram

Where: P = Power (Btu/hr), t = Turbine, c = Compressor, n = Net Power Output, m = mass (lb/hr) cp = specific heat (Btu/lbR, 0.24 for air, 0.2744 for combustion gas), T = temperature (R)

Humid Air Injection Power Augmentation for Combustion Turbines

Thus, as mentioned earlier and demonstrated in Equation 1 above, the power produced by the turbine (Pt) is proportional to the mass (m) flow in lb/hr. In addition, the power consumed by the compressor (Pn) is also a function of mass flow. In fact, the gas turbines axial flow compressor will consume about 60% - 70% of the power produced by the turbine (i.e. back work ratio), leaving only about 30%-40% power (Pn) to provide electricity (via a generator) or mechanical work for fans, pumps and compressors (i.e. gas pipelines). Whats unique and interesting about Air Injection is that the mass increase occurs after the compression cycle (high pressure point of the cycle, point 2), thus the work of the gas turbines axial flow compressor (Pc) is virtually unchanged and compressor blades and ductwork are unaffected. In addition, this power increase is instantaneous, thus making Air Injection technologies ideal for peaking or remote dispatch applications in addition to base load strategies.

Air injection increases mass flow at point 2, after compression cycle

Some technologies increase mass flow at point 1 and this increases compressor power requirements

The amount of power increase is limited by such factors as shaft torque, the compressor surge line and cooling capacity and ratings of the generator.

Part Load Performance

Another important consideration to keep in mind when analyzing your current operation or the various power augmentation technologies in the market today, is part load performance. Figure 4 demonstrates that HAI has a better part load performance than is possible with the existing combustion turbine and can operate over a greater range. This provides increased flexibility and opportunities for the operator. Figure 4: Part Load Performance Curves for a GE7EA
40

CTHAI Operating Range

35

Net efficiency,%

30

CTHAI CT
25

20

Typical Operating Range

15 0 20 40 60 80 100 120 140

Load, %

Humid Air Injection Power Augmentation for Combustion Turbines

NOx Reduction
Finally, we also touched on the potential for NOx reduction from the HAI technology. Figure 5 shows test data that was conducted by Textron (USA) and Aero Industrial Technologies on combustors operating with humid air. These tests showed that single digit measured NOx emissions are possible even for a relatively dirty diffusion type combustor operating on natural gas. Figure 5: Potential NOx Reduction with Humid Air Injection

1000.0 NOx PPM 100.0 10.0

Un sta ble

1.0 0.1 0 10 20 % H2O/AIR

30

40

Conclusion
Prudent owners, engineers and operators of combustion turbines must look at new ways of improving the performance of these assets in order to remain competitive in todays markets and to maximize shareholder value. Hill Energys Humid and Dry Air Injection technology is quickly becoming the technology of choice in terms of performance improvements, magnitude of the power enhancement, return on investment, simplicity of operation, dispatch ability and NOx reduction. Hill Energy uses sophisticated computer modeling (Gate Cycle, GT Pro, 8760 weather and rate data, etc) to analyze the performance of your combustion turbine (simple cycle, combined cycle, regenerative, two shaft, etc) in order to determine the limitations, dynamics, improvements and economics of your specific situation. We can provide a complete turnkey solution including: modeling; engineering, procurement and construction; project and construction management; financing; licensing and O&M services. Therefore, let us take a look at your existing combustion turbines or even those on the drawing board. We believe that we can help you be more competitive in todays market and improve your bottom line performance.

11757 Katy Freeway, Suite 1300 Houston, TX, 77079 Tel: 281-854-2164 www.hillenergysystems.com