Increasing the production capacity of turbocompressors in hot environmental conditions

Product introduction

One of the main issues with turbochargers in the country’s industries is the limitation in their production capacity in hot weather conditions, as well as the decline in their performance over time and the inability to compensate for this decline after repairs (due to the use of low-quality blades made by manufacturers other than the original turbine manufacturer). In this regard, Turbotek has relied on its design knowledge and experience in analyzing dual-shaft gas turbines to present an upgrade plan called Turbotune. The Turbotune plan addresses the challenge of exhaust gas temperature (T7) from the turbines on hot days by adapting the turbine to warm conditions. This plan increases the production capacity and efficiency of the engine in hot weather conditions. The upgrade is both hardware and software-based and can be implemented on the gas unit in less than 48 hours. By using this plan, the operating temperature of the exhaust from the gas turbine will reach a higher maximum allowable value at relatively higher ambient temperatures, and it will have the capability to produce more power under the same exhaust gas temperature conditions. Given Turbotek’s ability to design gas turbines, there is a possibility for the integrated implementation and modification of systems and equipment in this plan. Therefore, in addition to examining the impact of adapting the turbine to warm conditions on the performance of the gas turbine, its effects on other sections will also be analyzed based on structural considerations and equipment layout, as well as potential impacts on the production process and performance of the gas turbine.

Advantages of the turbocharger design

  • Increasing production capacity at high ambient temperatures
    Increasing engine efficiency at high ambient temperatures
    Solving the problem of gas turbine exhaust gas temperature limitation in site conditions
    Achievement of maximum permissible turbine exhaust temperature at relatively higher ambient temperatures
    Ability to produce more power at the same turbine exhaust temperature
    Reducing fuel consumption at high ambient temperatures

How it works

  • Optimization of power turbine nozzles (hardware)
    Optimization of power turbine nozzles according to environmental and performance conditions in order to increase gas turbine production capacity
    Adjustment of IGV control logic (software)
    Change of control logic of IGV changes in gas turbine according to hardware changes, environmental conditions and current state of gas turbine

    MW increase in power and 0.4% increase in efficiency at 50 degrees Celsius

Completed projects

  • Implementing the Turbotune project on many IGT25 gas turbines manufactured by OTC
    Successful implementation of the Turbotune project on one of the gas units of the Khoramdareh station, in order to reduce the exhaust temperature and increase capacity (15 degrees decrease in exhaust temperature while the gas flow rate through the line has increased by about 100ton/hr.)
    Implementation of the Turbotune project on 5 gas units of the 7th Asaluyeh Refinery (in progress)