Mirko Lepel, ABB Turbo Systems Ltd / GMC Nashville, 3rd Oct 2011

Field experience of turbocharger retrofits to fulfill emission regulations on reciprocating gas compression engines
ABB Group / ABB Turbocharging Standard E October 18, 2011

Turbocharger retrofits Why retrofit gas compression engines?

Why would a gas compression engine operator retrofit an engine? Retrofits can be a cost-effective alternative to complete gas compression plant retirement/replacement e.g. if:

Engine required to fulfill future emission limits. Engine is expected to continue operating for a few more years. Spare part availability of the old turbocharger is poor and expensive, or custom engineering is needed. Excessive downtime due to breakdowns of the old turbocharger. Excessive fuel consumption due to low efficiency of the old turbocharger having significant impact on operating costs. Technical support for old or discontinued turbocharger is unavailable. Improvement of field serviceability by turbocharger OEM and/or local maintenance crews. This minimizes downtime and repair costs.

ABB Group / ABB Turbocharging October 18, 2011 | Slide 2 | Standard E

Turbocharger retrofits Retrofit process

Engine data Customer requirements Site / operating conditions

Definition of air specification

Definition of turbocharger frame size and initial specification

Selecting turbocharger from standard portfolio

Performance evaluation Engine model validation Performance optimization by simulation Changing e.g. nozzle rings, diffusers and rotor components if required

Optimizing turbo specification according to engine tests

Validation of final turbocharger specification to customer requirements

ABB Group / ABB Turbocharging October 18, 2011 | Slide 3 | Standard E

Turbocharger retrofits Evaluation of data and performance optimization

Topology of engine model

Validated simulation tool with access to turbocharger database

ABB Group / ABB Turbocharging October 18, 2011 | Slide 4 | Standard E

Turbocharger retrofits Determination of frame size

Impact of mean effective pressure (bmep) for two different engines with identical power ratings on turbocharger frame size impact on turbo cost - $/KW
C
high bmep engine low bmep engine smaller frame size larger frame size

V298
ABB Group / ABB Turbocharging October 18, 2011 | Slide 5 | Standard E

Turbocharger retrofits Optimization of TC specification / modular TC design

Impact on changing compressor trim

6 .0
to t/to t

6.0
tot/tot

Impact on changing diffuser

v C

C
5.5

5 .5

5 .0

5.0

4 .5

4.5

nTC
4 .0

nTC
4.0

3 .5

3.5

3 .0

3.0

s V
2 .5

2.5

sV
2 .0

2.0

1 .5
** *sVsVV * s sV

1.5
* * *sV sVsV

1 .0 0. 5

1.0

1 .5

2. 0

2.5

3 .0

4.0 . 3 .5 V 98 [m /s] V2298 3[m 3/s]

1.0 0.5

1.0

1.5

2.0

2.5

V298 [m3/s]/s] V [m
3 298

3.0

3.5

4.0

ABB Group / ABB Turbocharging October 18, 2011 | Slide 6 | Standard E

Turbocharger retrofits Clark HSRA-8 engine with VTR304 field experience

San Diego Gas and Electric (SDG&E) compressor station

ABB VTR304-32 turbocharger

with external, anti-friction bearings ideal when engine oil is not easily supplied to the turbo Jet Assist is available on request to improve the rotors acceleration and subsequently the load acceptance of the engine

ABB Group / ABB Turbocharging October 18, 2011 | Slide 7 | Standard E

Turbocharger retrofits Clark HSRA-8 engine with VTR304 field experience

gas

Topology of Clark HSRA-8

ambient jet assist scavenging piston air

Air receiver

comp

Exhaust receiver

turb

ambient

exhaust waste gate

Scavenging piston to assist gas exchange and stabilize the combustion

ABB Group / ABB Turbocharging October 18, 2011 | Slide 8 | Standard E

Turbocharger retrofits Clark HSRA-8 engine with VTR304 field experience

Measurement results by AETC

BSFC vs. B.S.NOx Moreno Valley Units #1 and #3 Pre and Post Conversion Test Full Load
1 0'5 0 0

Benefits of the retrofit

Emissions reduced below requirements Fuel consumption slightly reduced Spare parts availability guaranteed Capital cost avoidance (retiring and replacing compressor plant)

Unit 1 Pr e-Conversion CB13 Cooper T C Unit 3 Post-Conversion ABB VT R304-32 Oct 28, 2010

1 0'0 0 0

B SFC (B TU/B HP -H R)

9'5 0 0

9'0 0 0

8'5 0 0

8'0 0 0 0.0 0 .5 1.0 1 .5 2.0 2 .5 3 .0 3.5 4 .0 4.5 5 .0

B.S. N Ox (g/B HP -H R)

ABB Group / ABB Turbocharging October 18, 2011 | Slide 9 | Standard E

Turbocharger retrofits
Cooper-Bessemer 12Q145HC with TPL-73 - field experience

PG&E Los Medanos injection plant

Benefits of the retrofit

Simulation and TC layout

Fulfillment of emission compliance Reduced fuel consumption Spare parts availability guaranteed Capital cost avoidance (retiring and replacing compressor plant) Full load availability of engine at high ambient temperatures (no derating)

ABB Group / ABB Turbocharging October 18, 2011 | Slide 10 | Standard E

Turbocharger retrofits Requirements for a successful retrofit project

Effective project planning Engine knowledge (understanding of operational effects of modifications) Accurate air specification for turbocharger Predictive tools for emissions reduction, air consumption, etc. Accurate measurements for baseline engine and subsequent testing

ABB Group / ABB Turbocharging October 18, 2011 | Slide 11 | Standard E

Turbocharger retrofits Benefits of a successful retrofit project

Emission reduction at or below requirements Fuel efficiency improvements Spare parts availability guaranteed Improved turbocharger reliability Minimization of downtime Full load availability at increased ambient temperatures (no derating) Capital expenditure avoidance

ABB Group / ABB Turbocharging October 18, 2011 | Slide 12 | Standard E

Thank you for your attention! For further information please visit us at our booth 100/102
ABB Group / ABB Turbocharging Standard E October 18, 2011

 ABB Group / ABB Turbocharging October 18, 2011 | Slide 14 | Standard E