ECT Technology Energy Conservation Turbines for MicroCogeneration

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ECT TechnologyEnergy Conservation Turbines for
Micro-Cogeneration

• Alonso CarvajalATTS Energía S.A.
• Cali Colombia
• www.atts-inc.com
• ATTS Inc. (USA) TurboTech Precision Engineering
  (India)
• 4º Encuentro de Uso Racional de Energía
• UPME - ANDI

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ECT Steam Turbine Cogeneration System
FREE POWER !
HP Steam
Chimney
Boiler
Flue Gas
Fuel
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Operating Principles of a Simple BP Steam Turbine

• Pressure Energy in the steam is converted to high
  velocity in the nozzle (about 1,800 km/hr)
• The high-velocity steam is impinged on the blades
  on the turbine wheel, which are thus given a
  kick (impulse)
• The turbine wheel rotates the generator to
  produce electricity

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What Happens to the Steam?

• In the process, the steam pressure is reduced in
  the PCV to the controlled usage pressure, and
  then flows to the process.
• In the turbine, the Enthalpy decreases only to
  the extant of electricity generated.
• The steam after passing through the turbine is
  available for process heating purposes.

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Aerospace Technology Applied to Small Industrial
Turbines

• Combined experience of more than 100 years in the
  Aerospace Engine Design Development Field
• Aerospace Design Tools
• 3D-CAD/CAM, FEM, CFD, Rotor-Dynamics
• High Speed High Efficiency for small
  turbines (Speeds up to 60,000 RPM)
• True Aerodynamic Blading designed using the
  latest Computer-Aided Software Tools
• High-Strength Aerospace Materials for long life

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Unique Technology of ECT

• Specially designed for Retrofit to Existing Steam
  Systems
• ANY INLET PRESSURE (UPTO 52 BAR 754 psi)
• ANY BACK PRESSURE (UPTO 18 BAR 261 psi)
• ANY TEMPERATURE (UPTO 520 C)
• ANY FLOW RATE (DEPENDING ON BACK PRESSURE)
• EVERY P.C.V is a potential ECT Application Point

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ECT Steam Turbine Features
Next
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Rotor Integrally Bladed Disk
Back
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Optimum Blading Design
Back
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Blading Custom Designed
Back
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Stainless Steel Casings
Back
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Vibration Isolation
Back
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Digital Control System
Back
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Integral Gearbox
Back
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Sealing
Back
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Induction Generator
Back
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High-Speed Bearings
Back
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Safety Benefits of Blisk Technology

• Machined from Solid Hardened Stainless Steel
  Forging
• High-Strength Design, No Joints
• Blading Aero-Dynamically Designed match to
  Customers Steam Conditions
• gt100 Over-Speed Margin

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E C T Blading Design Manufacture Digital
Design Manufacture
DIGITAL Transfer
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Compact Design

• Light and Small due to High-Speed Design
• Easy to Position, No Civil Works Required
• Rubber Isolation Mounts Dynamic Load Factor 1.0

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Induction Generation Process Integration is
Seamless

• Induction Generation is Ideal for Varying Steam
  Flow
• Voltage Frequency are Locked by Grid
• Only Current (and Power) vary with Steam Flow
• No Nuisance Trips if Steam-Flow Drops

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Digital Control System Easy to Integrate with DCS

• Allen-Bradley PLC-Based Controls (others)
• As Easy to Start Operate as Your Car Insert
  Key, Turn ON Turn Key to START
• NO DEDICATED OPERATOR!
• Automatic Health Monitoring Trips
• Can be Interfaced with Plant DCS

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Control Logic

• Key to ON (self-check)
• Turn key to START release
• PLC Actions (automatic)
• Ramp turbine up to synchronous speed by slowly
  opening Control Valve
• Close the breaker
• Switch over to Back Pressure Control (modulate
  Control Valve to keep Back Pressure at Set Point)
• Continuously monitor Health Parameters TRIP if
  necessary
• Fail-Safe control philosophy employed throughout
  (eg. Control Valve is power-to-open)

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Safety Features of ECT

• Rotor Blading Material gt900 MPa strength,
  safety factor 4 x of competition
• Rotor Blisk has gt 100 Burst Speed Margin
  (Competition lt 25)
• Stainless Steel casing has gt 30 elongation for
  Large Fragment Capture and Retention
  (Competition WCB Casing 3 elongation)
• Tip Clearance for Rotor is 10 of Rotor
  Elongation Capacity, so Rub Stop during
  overspeed

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Rotor Dynamics of ECT

• ECT operates Super-Critically (critical speed is
  about 35 of operating speed)
• Response DECREASES as 100 is approached
• It is insensitive to Unbalance at Full Speed

Response
35
100
Speed
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TRIPS Commanded by PLC

• Emergency Trip Switch (Manual, Local or Remote)
• Over and Under Speed
• Low Lubricant Oil Pressure
• Low Control Air Pressure
• High Back Pressure
• High Bearing Temperature
• Electrical Protection Relays (OLR, OV, UV, etc.)
• Vibration Switch (optional)
• User Defined Condition (optional)
• ALL TRIP CONDITIONS WILL RESULT IN POWER TO
  CONTROL VALVE BEING CUT, RESULTING IN QUICK
  SHUT-OFF BY THE SPRING IN THE ACTUATOR.
• THE PLANT PCV WILL THEN OPEN AUTOMATICALLY AND
  CONTINUE STEAM FLOW UNINTERRUPTED TO THE PROCESS

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Case Study ECT Cogeneration in a Process Plant

• Plant Steam Consumption 14.97 TPH 33,000 p/h
• Saturated Steam 300 ºC
• Boiler Pressure 22.43 kg/cm2(g) 320 psig
• Usage Pressure 3.06 kg/cm2(g) 44 psig
• Generated power 800kW /- 3

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Case Study ECT Cogen in a Process Plant

• Power generated by ECT 800 kW
• Annual Savings (_at_ US 0.108/kWh)about US
  645,000
• Total Investment (ECT Installation)ltUS
  970,000 _at_ 78 IRR
• Pay-Back lt 1.5 Years
• Savings over 15 Year Life about US 4,700,000

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Steam Turbine ECT Mark 3

• 50 160 kW
• Induction Generator Only

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Steam Turbine ECT Mark 4

• 800 2500 kW, 1,2 ,3 or 4 stages
• Induction and Synchronous Generators
• Back-Pressure and Condensing / Extraction

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Steam Turbine ECT Mark 7

• 160 800 kW, 1,2 ,3 or 4 stages
• Induction and Synchronous Generators
• Back-Pressure and Condensing / Extraction

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100 ECT Fleet in 15 Indian States 7 Export
Markets
Kerala-6 Tamilnadu-10 Karnataka-6 Andhra
Pradesh-13 Goa-3 Maharashtra-24 Gujarat-11
Madhya Pradesh-7 Uttar Pradesh-4 Bihar -2
W.Bengal-5 Assam -1 Rajasthan-3 Himachal
Pradesh-3 Punjab-2 Taiwan-2 Dubai-2 Sri
Lanka-1 Saudi Arabia-1 S.Korea-1 Nepal-1 Thailand-
1
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Opportunity for Carbon Trading

• TurboTech will act as Aggregator to obtain UN
  Certification share Carbon Credits with
  Customer
• Annual Revenue will depend on Power Rating of ECT
• Every 100 kW will prevent 876 Tonnes of CO2
• Each Tonne CO2 will be eligible for 14 20 in
  Carbon Credits
• Each 100 kW 12,000 17,000 in Carbon credits

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Conclusion

• Cogeneration is now feasible even in SMALL
  installations with SATURATED STEAM ALL boilers
  can be POWER BOILERS
• RETROFIT of existing steam systems with Energy
  Conservation Steam Turbines (TurboTechs ECT) is
  easy, and will result in Large Money Savings and
  Environmental Benefits

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ATTS Energía S.A.ventascolombia_at_atts-inc.com
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New Products in Pipeline

• Low-Cost Gas Turbine 500 kW
• Micro-Gas-Turbine 55 kW
• Solar-Thermo-electric System
• Biomass Fired Gas Turbine

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LCGT First Indian Gas Turbine for Micro-Cogen
500 kW
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Micro-Gas-Turbine 50 kW