GAS TURBINE EXHAUST SYSTEMS

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www.compact-global.com

The rising market share of renewable energy leads to the discussion about co-gen or

combined cycle? Quite a number of co-gen power stations have faced preservation, right

after commissioning. A Bypass System integrated between the Gas Turbine and the

Waste Heat Recovery Boiler would have provided these power plants with the necessary

flexibility to react to the ever changing electricity demand of the markets - would have

made such power plant investments into much safer investments. Features like all time

cold start availability, simple cycle operation to respond to grid demand, combined cycle

at all time and grid stability by quick change over – this flexibility of a Bypass System

makes a modern gas turbine power plant into profitable investments.

We are an aspiring company: innovative, ambitious, and meticulous in development.

The power generation industry world-wide has confidence in our technology, it is new,

different, reliable and based on millions of operating hours of experience. Customers

appreciate our competence, our latest and patented technologies, our engineers‘

reliability and their creativity. Benefit from our solutions.

Keep it flexible

Yours

Peter Alexander Prochazka

Managing Director (CEO)

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When we set our first modulating diver-

ters 1996 into operation, the results were

overwhelming. We installed our pivot

diverter design and it was confirmed that

this is the safest diverter design.

The pivot diverter is the ideal choice

for a safer operation!· No toggle lever linkage inside

· No hot bearings inside

· No cold shaft once the flap is in bypass

close position

Diverter 3.0The third generation, our latest and

patented design, is a new milestone in

the exhaust system technology. A counter

weight balanced power train, makes

the hydraulic drive systems obsolete -

even for giant diverters. Considering the

reduction of plant self consumption, the

savings on investment and later operation

and maintenance cost; it is a major contri-

bution to the environment.

GRAVIMOV® - The new Diverter power train

Benefits at a glance· Balanced operation in any modulating

angle position – Balanced Drive Concept

· Vibration free modulation without any

limitation of position

· Balanced flow distribution for an

optimized pre-heating of the HRSG

· Less fuel consumption due to shorten

pre-heating time

· Minimized maintenance cost

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EXHAUST GAS FLOW SIMULATION FOR GE 6FA GAS TURBINE

DIVERTER FLAP 60° OPEN

Vibration free in any

modulating positionThe GRAVIMOV® power train keeps

the diverter flap vibration free in any

modulating position from 0° to 90°

Optimized gas flow and lowest

back pressureEach of our deliveries are simulated by our

in-house CFD department. We optimize

the gas flow distribution to its best

performance and lowest back pressure.

All documented in modulation curves

especially prepared for each individual

installation.

Unlimited modulation The diverter flap design provides over-

flow openings in any modulating position

by a given distance between the top end

of the flap and the shaft. The modulating

efficiency is drastically increased by a

flow at the diverter flap tip and by a flow

crossing over the diverter flap. The effect

to the HRSG is tremendous, because we

are able to lower the pre-heating period

necessary for the HRSG.

Balanced flow distribution The flow distribution is balanced over the

entire surface of the HRSG for an opti-

mized stress-free and shorter pre-heating

process – resulting in enormous fuel

savings for those power stations in conti-

nuous flexible operation.

GRAVIMOV® - The Diverter power train

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Why lose megawatts

Megawatts of energy losses, every 8000

to 16000 hours a shut-down to exchange

lamella seals - this is definitely no solution

for modern power plant equipment

anymore. NEVEXseal® solves all these

problems and stays forever gas tight with

100 % sealing efficiency.

Modulation in all positions

A minimum of exhaust gas flow towards

the HRSG is no problem for this new

seal system. Set the diverter flap a few

millimeter from the seal seat and keep

the HRSG warm for any combined cycle

quick start, with NEVEXseal® no problem.

Develop new operation modes, because

of NEVEXseal®.

Lamella seals are history

Lamella seals are required in any speci-

fication about diverters. Lamella seals

do not last long. Energy losses are

pre-programmed. High grade alloy lamel-

las cost a lot of money. The shutting down

of the gas turbine for the exchange

of lamellas seals is costly and creates

operation losses.

The solutionFor years we have been searching for a

better solution to replace lamella seals.

With our recently patented free floating

none segmented seal seat we developed

the touch-free seal seat. Once installed it

lasts forever – forever gas tight.

NEVEXseal® - The Energy Saver

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The targetWe wanted a silencer more compact with

best flow dynamic performance, with less

thermal elongation, with less mechanical

load, more economical, easier to maintain.

A silencer which needs less room, is lighter

and has a higher attenuation performance

over the entire frequency spectrum. With

the RESONABTOR® we have revolutio-

nized the silencer baffle design and put

the as yet known technologies into the

past.

3-D sound attenuationA combination of a resonator with an

absorber in a high to width dependence

having a silencer with two different

absorber depth. The orientation of the

two different absorber depth in the

silencer casing attenuates low and high

frequencies.

Flow straightenerThe arrangement of the RESONABTOR®

lowers the pressure drop tremendously

compared to historical silencer baffles,

because of the flow straightening effect

the RESONABTOR® has.

Over 1000 RESONABTOR® installed For almost all major brands and types

of gas turbines we have installed the

RESONABTOR® with very best results,

much better than what silencer baffles are

able to provide and with a much lower

pressure drop to the benefit of the gas

turbine performance. The RESONABTOR®

is ideal for replacing old silencer baffles in

existing installations.

RESONABTOR® - The Silencer of the future

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Silencer performanceVarious and continuous changing opera-

ting states, high temperature, turbulent

flow, self generated noise due to high gas

velocity, are the minimum requirements

for a silencer apart from damping

the sound emission coming from the gas

turbine.

Reflection, Diffraction and Refraction

The RESONABTOR® is a very complex and

highly effective labyrinth system. Diffrac-

tion is a mechanism that let the sound

energy follow the shape of the extremity

and lead the sound wave into shadow

zones. Long low-frequency waves are

bent more than high-frequency waves,

they are directed into the next crosswise

placed absorber section. Edge diffraction

means exponential splitting into particles

with the same frequency which are super-

imposed according to the scattering of the

direct beam passage. The integrated

Helmholtz Resonators additionally

attenuating low frequencies.

Jacket flow

With the configuration of the RESONAB-

TOR® we concentrate higher gas speed

into the center of the flow column. The

stack outlet speed at the circumference of

the stack is lowered. The jacket flow has

the effect that sound propagation is

limited through strong shear layers of

different flow velocities. Flow noise at

the stack outlet is eliminated and sound

emission is damped to its maximum.

FLOW AT RESONABTOR® ENTRANCE

SOUND ATTENUATION IN THE RESONABTOR®

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The different approachWe did it differently from the beginning by

doing it systematically - frame by frame.

Minimized number of studs

And we further improved it: The number

of fixings to the cold casing have been

reduced by 50 % to minimize heat trans-

fer and structure-born sound. Sound at

1 m is now at around 72 dB(A) only, heat

transfer is less than 240 W/m² with a

outside casing surface temperature of

around 55°C.

Membrane absorber

Through the membrane structure - that

is by clamping the cladding sheets on

their circumference - the cladding sheets

can oscillate. The stiffener at the back grips

into the insulation material hence the

membrane is damped at the back. Frequen-

cies between 16 Hz and 500 Hz are

effectively attenuated.

quiteCool™ - The Internal Insulation

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Modular Panel SystemSeparating a bigger part into pieces is

not really sophisticated, but making it

systemized is sophisticated.

Easy to assembleThe panels come on site in a transport

rack, whether for round or rectangular

sections, they are ready to assemble. Only

at the corners panels will be joint bolted

applying a gasket in between the flanges.

Build up the exhaust system – stack one

section on top of the other and joint bolt

again. No welding work at site is the key

for thorough quality and for enormous

cost savings.

Easy to transportPACK & GO™ Exhaust System side-walls

are store into lifting racks, for multiple

handling and lifting. Standard sea-freight

container transport saves time and

money.

PACK & GO™ - Exhaust System

SAFETY FACTOR

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30 Years of ExperienceQuality by over 30 years of site experien-

ces: competent engineering and pioneer

work. That means, we have been provi-

ding a significant contribution for the

realization of modern gas turbine power

plants.

Success on a solid foundation Integrity, partnership, comprehensive

competence in plant engineering and a

unique passion and enthusiasm for our

work hallmarks us.

Added value by more performanceWith a range of products and services as

well as the strategic planning for turn-key

installation we offer complete solutions

from a single source. With a consistent

focus on continuous improvement we are

able to stay innovative and efficient in

every way.

Experience counts

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office@compact-global.com

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