Major challenges are related to compressor and driver integration during run down. In order to understand these challenges, the pipeline compressor facility at Troll Kollsnes gas treatment plant, Norway, has been subjected to detailed trip testing and dynamic simulation analysis. The plant includes five pipeline compressors and is utilised as a pilot for analysing the transient response of a 40 MW compressor driven by a variable speed electric motor. The compressor control and protection system include an anti-surge and a hot gas bypass system. Vibration records have shown that under power outage the compressors were exposed to violent vibrations. Further investigation revealed that during a short power outage, the compressor enters the surge- and rotating stall area under certain operating scenarios. The rotating stall response resulted in reduced operating range and flexibility for the pipeline compressors. Specific precautions had to be taken to prevent the compressor from running into the low flow operating area of the performance envelope. Dynamic simulations cover important aspects related to the transient scenario analyses performed to reveal the root cause of the compressor problems. The simulation system enables sophisticated plant models to be configured from high quality standard model algorithm building blocks. Verification of the model blocks have been performed against plant records in order to validate the transient predictions. The paper reports experience from testing and verification of compressor and driver integration with reference to transient behaviour during run down. This includes the validation of the dynamic models, which apply both to the design and commissioning phase where actual plant trip tests should be used to verify the design and stability margins.

Siemens Energy, Inc. was awarded a contract by the U.S. Department of Energy for the first two phases of the Advanced Hydrogen Turbine Development Program. The 3-Phase, multi-year program goals are to develop an advanced syngas, hydrogen and natural gas fired gas turbine fully integrated into coal-based Integrated Gasification Combined Cycle (IGCC) plants. The program goals include demonstrating: • A 3–5% point improvement in combined cycle efficiency above the baseline, • 20–30% reduction in combined cycle capital cost • Emissions of 2 ppm NOx @ 15% O2 by 2015. Siemens is currently well into Phase 2 of the program and has made significant progress in several areas. This includes the ability to attain the 2015 Turbine Program performance goals by developing component and systems level technologies, developing and implementing validation test plans for these systems and components, performing validation testing of component technologies, and performance demonstration through system studies. Siemens and the Advanced Hydrogen Turbine Program received additional funds from the American Recovery and Reinvestment Act (ARRA) in 2010. The additional funding serves to supplement budget shortfalls in the originally planned spend rate. The development effort has focused on engine cycles, combustion technology development and testing, turbine aerodynamics/cooling, modular component technology, materials/coatings technologies and engine system integration/flexibility considerations. High pressure combustion testing continues with syngas and hydrogen fuels on a modified premixed combustor. Advanced turbine airfoil concept testing continues. Novel manufacturing techniques were developed that allow for advanced castings and faster time to market capabilities. Materials testing continues and significant improvements were made in lifing for Thermal Barrier Coatings (TBC’s) at increased temperatures over the baseline. Studies were conducted on gas turbine/IGCC plant integration, fuel dilution effects, varying air integration, plant performance and plant emissions. The results of these studies and developments provide a firm platform for completing the advanced Hydrogen Turbine technologies development in Phase 2.

Siemens Energy, Inc. was awarded a contract by the U.S. Department of Energy for the first two phases of the Advanced Hydrogen Turbine Development Program. The 3-phase, multi-year program goals are to develop an advanced syngas, hydrogen and natural gas fired gas turbine fully integrated into coal-based Integrated Gasification Combined Cycle (IGCC) plants. The program goal is to demonstrate by 2010 a 2–3% point improvement in combined cycle efficiency above the baseline, 20–30% reduction in combined cycle capital cost and emissions of 2 ppm NOx @ 15% O2. The 2012 goal is for IGCC-based power with carbon capture. Furthermore, by 2015, the goal is to demonstrate a 3–5% point improvement in combined cycle efficiency above the baseline, and 2 ppm NOx @ 15% O2. Recent activities have focused on the initiation of Phase 2. This included developing component level technologies and systems required to meet the 2010 and 2015 project objectives, developing validation test plans for systems and components, performing validation testing of component technologies, and demonstrating through system studies the ability to attain the 2010 and 2015 Turbine Program performance goals. The development effort was focused on engine cycles, combustion technology development and testing, turbine aerodynamics/cooling, modular component technology, materials/coatings technologies and engine system integration/flexibility considerations. The first series of oxidation and coating compatibility testing of modified superalloys was completed. High pressure combustion testing was performed with syngas fuels on a modified premixed combustor. High pressure testing of a second premixed combustion system was also performed. Novel turbine airfoil concept testing continued. Conceptual design reviews and risk analyses were carried out on new gas turbine components. Studies were conducted on gas turbine/IGCC plant integration, fuel dilution effects, varying air integration, plant performance and plant emissions. The results of these studies and developments provide a firm platform for completing the advanced Hydrogen Turbine technologies development in Phase 2.

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The Gullfaks ‘A’ Platform located in the Norwegian Sector of the North Sea, is designed to process 50,000 SM3/day of well head fluids to crude oil and gas product specifications. The present operating conditions of the process are different from the original design due to changes in feed stock. Furthermore, degradation of compressor performance due to fouling, wear and internal leakage has led to limited production flexibility. Field performance testing of the compressors has been carried out supplemented by computer based performance prediction. Based on this information, a dynamic simulation model of the process, tuned to actual plant operation, has been used to analyse the process behaviour. Modifications have been studied by dynamic process simulation before field implementation. These modifications have resulted in reduced operating and maintenance costs. Substantial decrease in compressor speed and load have led to reduced wear and maintenance. Operational and pollution tax savings are estimated at $1.5m/year.