Thermal Acoustics

Gas Turbine Exhaust Systems & acoustical components

www.aarding.com

page 3

introduction

Aarding Thermal Acoustics was established in 1960 and has grown to a strong and flexible company. Our strength comes from our extensive know-how on a wide variety of acoustical components and GT exhaust systems. Our customers are Gas Turbine manufacturers, Power Producers or Contractors. Whether a problem can be solved from our standard product line or needs a tailor made solution, Aarding Thermal Acoustics takes control from design to installation. Even for complex turn-key retrofit projects. Aarding Thermal Acoustics is management owned therefore we can operate flexible and fast on customers demand. It is no surprise that we have grown

General

GT exhaust gas systems

4
Acoustical Components Markets

16
Aarding projects

20
offices around the world

into an international corporation as the trusted name for acoustical components and Gas Turbine exhaust systems for Power Plants.

26

28
Martin Pranger and Norbert Pieterse

+
1 2 3 4

page 5

Effective solutions for the Power and Petrochemical Industry worldwide. Design , Engineering, Manufacturing and Supply of Gas Turbine Exhaust Systems and Acoustical Components

Capabilities
The current market environment is pushing the ope-

Gas Turbine Exhaust Systems (*)

+ Diffusers, Plenum and Gas Turbine Exhaust ducts + Single cycle exhaust systems + Bypass Exhaust systems + Exhaust Stacks + Thermal Insulation + Boiler Internals

Exhaust Diffuser / Exhaust Plenum Exhaust Duct Exhaust Bypass System Silencer

5 6 7 8

Exhaust / HRSG Inlet Duct HRSG Internal Insulation Vent Silencer Stack

rational conditions of Industrial Gas Turbine systems to its limits. High cycling (high numbers of starts and stops) as well as high local flue gas velocities and temperatures are putting large stresses on the exhaust gas systems. Environmental regulations require stringent and lower noise levels on gas & steam turbine driven systems as well as on petrochemical applications.

7 4

Acoustical Components (*)

+ Vent silencers for steam and gas applications + In-line diffusers + Flue gas silencers + Commissioning silencers Both New as well as Upgrade / Retrofit systems Design and Engineering is realized in-house by our teams of experienced engineers specialized in mechanical, thermal and acoustical engineering dedicated for the Power and Petrochemical Market. Manufacturing is realized worldwide, providing the most economical solution and optimal logistical project realization. All systems are manufactured according to strict quality levels and standards and manufacturing supervision and quality control is realized by experienced Aarding Inspectors.

Aarding Thermal Acoustics is an established, independent and privately owned company with its headquarters in the Netherlands and supporting offices & partners worldwide (USA, Latin America, Eastern Europe/ Russia, Middle East and Asia)

8 4 3

Based upon a proven track record Aarding Thermal Acoustics provides customized and turn-key solutions. Our scope includes; Design, Engineering, Manufacturing and Supply of;

6
(*) All major gas turbine, HRSG and petrochemical systems

General

page 7

DIFFUSERS / PLENUMS (1)

One of the major transition areas between the gas turbine exhaust and the exhaust system is the diffuser duct or gas turbine exhaust plenum duct section. On the larger & newer type IGTs the exhaust gas flow is directed into the exhaust system through a diffuser duct (straight flow) and on some specific type IGTs through a gas turbine exhaust plenum duct section changing direction of flow into a 90 degrees bend.

For both systems Aarding Thermal Acoustics provides diffusers and plenums specifically engineered to cope with the strong GT exhaust gas swirl characteristics as well as the high GT exhaust gas velocities and temperatures. To accommodate start stop operation as well as operation at elevated temperatures, Cold casing designs specifically engineered for the applicable operational conditions are the current standard.

GT Exhaust Systems
1 2 2

GT EXHAUST DUCTS (2)

Exhaust ducts are mainly applied as transition between diffuser and diverter systems or between the diverter system and HRSG (inlet ducts). Main design focus is related to the high swirls, exhaust gas velocity and elevated temperatures. Aarding Thermal Acoustics designs and provides the latest cold casing design adapted to todays stringent

operational conditions. Ducts are commonly engineered including additional features such as dedicated silencer assembly supporting systems Accommodating high gas flows and start stop operation), turning vanes, fast opening & closing access doors and compensator connection flanges. In addition, all systems are designed to meet both thermal (maximum surface temperatures) and acoustical (noise levels) requirements based on either local or governmental requirements.

GT Exhaust systems

+
start-stop cycles.

page 9

Aarding provides the design, manufacturing, and supply of the complete scope of supply from the inlet expansion joint through the stack exit.

Single Cycle Exhaust Systems

In todays energy market there is a growing demand for peaking power. Simple cycle operation is a fast and reliable way to provide flexible power demand at short notice. Aarding Thermal Acoustics provides a range of alternatives on simple cycle exhaust systems which will support effective cyclic operation and the changes in thermal load which are part of the frequent

Aarding Thermal Acoustics will do the design, manufacturing, and supply of the complete scope of supply from the inlet expansion joint through the stack exit. Our in house acoustical capabilities are backed up with extensive laboratory and field measurements which allow us to develop state of the art solutions for your noise control requirements. Aarding has extensive experience in the supply of simple cycle exhaust systems and supplies either sections of the system up to the complete exhaust systems including on-site erection and commissioning.

Each design is individually designed for internal stud spacing, stud size, liner plate thickness, to ensure the best operational conditions and unit lifetime.

GT Exhaust systems

With optional seal air systems we can guarantee zero leakage and a man safe environment for any maintenance to the HRSG.

+
Bypass Exhaust Systems
To realize higher efficiency levels gas turbine waste heat is used to generate process steam or steam turbine operation. Aarding Thermal Acoustics provides Bypass Exhaust Systems between gas turbines and HRSGs. These Bypass systems allow flexible operation of the power island as well as the capability of starting the gas turbine in rapid starting mode and allowing the HRSG to gradually come online. This approach gives offers the flexibility of fast power and increases the life of an HRSG. In todays business environment bypass exhaust systems provide a solution for the option between baseload and peaking/ modulating operation. Aarding Thermal Acoustics Bypass Exhaust Systems and fitted with state of the art diverter systems from our partners in the USA and Canada. The diverter valves can be designed as pivot or toggle type and can accommodate both hydraulic and electric drives. With optional seal air systems zero leakage and a man safe environment for any maintenance to the HRSG can be provided.

page 11

GT Exhaust systems

page 13

Exhaust Stacks
Advanced type gas turbine operation requires high performance of the insulation systems, silencer assemblies and supporting systems of Exhaust stacks. Noise regulations often demand complex design silencer systems and turbine exhaust gas temperatures require a dedicated thermal design. Existing and ageing stacks often show extensive wear since most older designs have difficulty coping with the current operational strains. Aarding Thermal Acoustics has developed effective internal stack insulation systems and can offer a combination of the most economical and effective stack system including stack design, support structures and auxiliaries as well as a silencer system which will offer both long term operation as well as excellent mechanical performance. A complete scope can be supplied including silencers, stack dampers, FAA lights, lightning protection and other related requirements. Based upon our experience we are able to offer complete turnaround projects in line with industry requirements and leadtimes.

Aarding can supply the complete scope including silencers, stack dampers, FAA lights, lightning protection, and more.

GT Exhaust systems

With the experience of more than 750 references worldwide, Aarding has the know how to execute the complete engineering in-house.

+
Internal Insulation
Cold Casing Design Aarding Thermal Acoustics has developped an in-house design of internal insulation systems based upon the latest operational requirements and newest materials. In our cold casing design, the insulation system is fitted to the casing interior using a custom designed support system. The protective sheeting is engineered based upon the most economical & effective distance (insulation thickness) from the cold outer casing wall by studs, nuts and washers enabling free thermal expansion of the metal sheeting in relation to the outer casing wall (floating plate principle). Aarding Thermal Acoustics design includes: +  Lower exterior duct/casing temperatures resulting from the use of custom designed internal insulation +  Eliminating or reducing external duct sliding connections applying cold design +  Ease of maintenance as a result of sectional design of internal insulation and optimised field joint designs +  Minimizing external duct movement resulting in longer duct life and less strain on flexible joints/ bellows +  Options to include higher temperature operation as a result of GT upgrade or installation of additional burner systems Typical designs; + Attic and basement baffles + Sealing plates + Side gas baffles + Center gas baffles + Flow baffles + Sound baffles With the experience of more than 750 references worldwide, Aarding Thermal Acoustics has the know how to execute the complete engineering in-house in combination with the supply of the complete insulation package.

page 15

Boiler Internals
Aarding Thermal Acoustics provides HRSG baffles. These baffles are normally located direct within the flow of hot exhaust gas through the heated surfaces of the HRSG / boiler (harps or modules). These baffles minimize gas bypassing the harps or modules and maximize the exchange of heat in the harps or modules where steam is generated. Aarding Thermal Acoustics design includes: +  The most effective distribution of gas flow over the boiler tubes. + The optimum flue gas velocity. +  Elimination of hot spots caused by bypassing flue gas.

GT Exhaust systems

Acoustical Components

page 17

Aardings blow-off silencer ensures that the noise production is kept at an acceptable level.

Atmospheric Vent Silencers

Aarding Thermal Acoustics Atmospheric vent silencers are typically used in conjunction with a relief/safety valve or a start up valve. Applications are in heat recovery systems, steam boilers, and at oil/gas/ chemical processing plants. The Aarding Thermal Acoustics vent silencer effectively eliminates high, unwanted noise at the source and provides for low sound level discharge to the atmosphere. This type of design is a reactive/ absorptive type of silencer. Aarding Thermal Acoustics vent silencers are custom designed for each and every application ensuring the best acoustical performance and can be designed for any service condtions or flow rates from as low as 1,000 lbs/hr to upwards and exceeding 1 million lbs/hr.

temperature) and provides 35-40 decibles of noise reduction. Additional reduction in total noise is achievable if required with an acoustic splitter package installed at the outlet of the silencer. This design with splitter package can provide for over 50 decibles of noise reduction. The silencers can be rented for use during commissioning of new systems or after extensive maintenance activities. The silencer is skidded for shipment and installation. The unit can be easily installed and connects the supported and restrained temp

In-Line Diffusers
The Aarding In-Line Diffuser assembly is designed to reduce the noise typically associated with pressure reducing valve applications. These in-line diffusers are of the diffusing type designed for the reduction of excessive noise from pressure reduction systems for steam, gas, air, or other mixed gas type services and are especially effective when used in combination with a valve to achieve and/or share the total pressure drop required by the system. The In-Line diffusers provide several functions:

Commissioning Silencers for Rental

Aarding Thermal Acoustics commissioning silencers are designed for steam systems to vent down during commssioning allowing the systems to clean and to get rid of possible remnants & deposits present within the systems located upstream. The Aarding Thermal Acoustics commissioning type silencer is designed to reduce noise pollution caused by high pressure gasses rapidly venting to the atmosphere during commissioning. This silencer is custom designed to vent approximately 1.2 million lbs/hr of steam (depending on steam pressure/

Dispersing high pressure reductions typically seen at pressure reducing valves and regulators, and air cooled condensers down to vacuum conditions. Dissipating high energy noise and reshaping the frequency spectrum, shifting the peak frequency to a higher octave band.

Acoustical components

page 19

Flue gas Silencer

Aarding Thermal Acoustics Flue gas silencers are custom designed to keep noise emissions within acceptable levels. Current gas turbine operation requires the latest design, engineering and advanced material selections. Whether flue gas silencers are mounted in a silencer duct, a hot or cold stack or have to be able to operate in high flue gas velocities or elevated and fluctuating temperatures (start-stop mode), Aarding Thermal Acoustics can provide the most effective solution in line with Gas Turbine output and Single cycle or bypass/HRSG design considering basic design criteria such as; + S  ound power level/noise output of gas turbine + N  oise requirement of power plant required dynamic insertion losses of silencer + P  ressure drop requirements + D  imensions of duct/stack + O  ther noise sources, e.g burners + O  ther noise reducing parts of the system, e.g. Boiler & elbow + M  aximum flow velocity The Aarding Thermal Acoustics Flue Gas Silencer offers the following advantages; +  In-house design by our team of acoustical engineers & experts +  Most effective and economical design +  Patented designs +  Fabrication based upon a full welded construction

Aardings Flue Gas Silencers have been designed by our in-house team of acoustical engineers & experts

Acoustical components

page 21

markets
Aarding Thermal Acoustics provides products and services from to the following markets: +  Power Energy Market +  Petro Chemical Market +  Aero Engine Market

Petro chemical Market

There where over pressure of several gasses is applicable, the products of Aarding can be delivered.

Aero Engine Market

Aarding Thermal Acoustics provides new as well as retrofit silencer and exhaust systems for Aero Engine test cells and hush houses. Major strength of Aarding Thermal Acoustics is an extensive experience and in house engineering and engineering techniques providing solution driven designs, products and services. Aarding Thermal Acoustics focus is on high temperature insulation applications and acoustic engineering.

Power Energy Market

Within the Power Energy Market, the products of Aarding Thermal Acoustics can be placed within: +  Coal Fired Power Plants +  Gas and Oil Fired Power Plants +  Nucleair Power Plants Aarding Thermal Acoustics supplies worldwide the products to end-users, EPCs, turbine suppliers, boiler suppliers and engineering-contracting companies for eventual balance of plants solutions.

markets

page 23

Service & Retrofit Market

Aarding Thermal Acoustics provides products and services both for new projects as well as within the service and retrofit markets. Repair on these ageing exhaust systems has its Todays changing market conditions with a growing and ageing fleet of heavy industrial equipment and requirements for a higher flexibility and higher output is stretching the boundaries of component life. Aarding offers a range of services either extending life, upgrading or retro fitting existing exhaust gas systems and acoustical systems. Many Older type Gas Turbine units face extensive wear and tear in the exhaust system. Minor defects in the insulation package often result in a fast and Aarding Thermal Acoustics provides engineering solutions including upgraded materials, a better insulation package and advanced engineering simulation techniques to ensure effective thermal and acoustic design of the exhaust system. limitations as a result of damages by hot spots and progressive base material degradation. As a result patch up repairs will not provide an effective operational solution and upgrade or replacement are the only options for life extension of the system. widespread damage increasing the number of trips and reducing availability.

markets

markets

page 25

A A Aarding office

Aarding projects
Africa
+ + Sidikrir & El Atf, Egypt Supply of internal insulation and boiler internals Supply of internal insulation for bypass stacks Arzew, Algeria Supply of internal insulation and boiler internals Supply of bypass flue gas silencers + Keppel, Singapore Supply of steam vent and flue gas silencers + BangPa, Thailand Supply of steam vent silencers + Samalkot, India Supply of steam vent and flue gas silencers + Mukhaizna, Oman Supply of internal insulation and boiler internals

Our strength comes from our extensive know-how on a wide variety of acoustical components and GT exhaust systems.

Australia & New Zealand

+ Pinjarra I & II, Australia Supply of exhaust gas systems and flue gas silencers + Yarwun, Australia Supply of steam vent silencers + Huntly, New Zealand Supply of exhaust gas systems

Middle East

Asia

+ Mapta Phut, Thailand Supply of exhaust plenum ducts + BLNG Shell, Brunei Supply of exhaust ducts + Gwang Gyo, South Korea Supply of steam vent silencers + Sengkang, Indonesia Supply of steam vent silencers

+ Tabuk, Saudi Arabia Supply of simple cycle exhaust systems + Rafha, Saudi Arabia Supply of simple cycle exhaust systems + Al Rasheed, Iraq Supply of simple cycle exhaust systems + Rabigh 6, Saudi Arabia Supply of steam vent silencers + Fujairah, UAE Supply of steam vent silencers + Qatargas, Qatar Supply of exhaust gas systems

+ Hines II, USA Supply of internal insulation and boiler internals + Brazos Valley, USA Supply of exhaust gas systems and flue gas silencers + Richmond County, USA Supply of steam vent silencers + Greenfield, Canada Supply of steam vent silencers

+ + + + + + +

Manzanillo, Mexico Supply of steam vent and flue gas silencers Belgrano & San Martin, Argentina Supply of steam vent silencers Termoflores II & III, Colombia Supply of steam vent silencers Tamare & Bachaquero, Venezuela Supply of internal insulation and boiler internals Hemweg & Diemen, the Netherlands Supply of internal insulation and boiler internals Magnum, the Netherlands Supply of internal insulation and boiler internals Ivago Gent, Belgium Supply of exhaust gas systems

Latin & South America

EUROPE

North America

+ Wayne County, USA Supply of steam vent silencers + Sutton, USA Supply of steam vent silencers + El Segundo, USA Supply of internal insulation and boiler internals

+ Pemex Nuevo, Mexico Supply of exhaust gas systems + Pemex Tabasco, Mexico Supply of exhaust gas systems + UTE Parnaiba, Brazil Supply of simple cycle exhaust systems + Pilar, Argentina Supply of steam vent and flue gas silencers

+ Baglan, UK Supply of intern insulation system + Corby, UK Supply of exhaust ducts + AES ELSTA Supply of exhaust ducts + Tuapse, Russia Supply of steam vent and flue gas silencers + Megalopolis, Greece Supply of steam vent silencers + Te-to Zagreb, Croatia Supply of internal insulation system and flue gas silencers

aarding projects

page 27

offices
Headquarters
Industrieweg 59 P.O. Box 65 8070 AB Nunspeet The Netherlands T +31 341 252635 F +31 341 262112 E-mail [email protected]

Office Asia
21 Bukit Bakot Crescent Wcega Tower #12-79 Singapore 658065 Singapore T +65 6631 4852 F +65 6631 4853 E-mail [email protected]

Office North america

2140 Eastman Avenue Suite #207 Ventura, CA, USA T +1 805 644 4629 M +1 805 603 9122 E-mail [email protected]

office south america

Rua Henri Dunant, 1301 sala 5, Chacara Santo Antonio Sao Paulo /sp Brasil E-mail [email protected]

Agente per l'Italia MANFREDDA & PARTNERS SAS PO BOX 73 - Via Flora 43 Tel. +39 0331 546430 Fax +39 0331 1817147 I: www.manfredda.com M: [email protected]

www.aarding.com