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CASE STUDY
SAUDI ARAMCO
POWER PLANT
TURBINE INLET AIR COOLING
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01 ABOUT ARAMCO
01
ABOUT ARAMCO
Saudi Aramco, officially the Saudi Arabian Oil Company is well known as the Given the magnitude of Aramco’s reserves and production it is considered the
biggest Oil & Gas Company in the world, with the largest crude oil reserves and world´s most valuable oil company. Their average daily crude production is
the highest daily oil production. 10.2 million barrels per day (BPD) meaning one in every eight barrels of the
world’s oil supply. More than 65,000 workers worldwide!
Over the past 80 years they have become a world leader in hydrocarbons
exploration, production, refining, distribution and marketing.
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02 WHAT DID ARAMCO NEED?
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WHAT DID ARAMCO NEED?
In 2013, Aramco continued with its expansion building three greenfield gas-
fired power plants in Saudi Arabia.
These power plants represent a total electrical generating capacity of 770MW.
The turbine models are General Electric Frame 7 EA and Frame 7 FA.
In each location Aramco installed 2 new gas turbines and their main aim was
to improve their efficiency and augment a power from to all of them.
Aramco needed a company with vast experience in power augmentation
systems and the ability to comply with highly demanding Oil & Gas standards
alongside high levels of quality assurance. For this reason they contacted
ARANER.
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03 ARANER SOLUTION
03
ARANER SOLUTION
The proposed power and efficiency augmentation technology was the Turbine With the modular solution, site works are reduced to the minimum possible. The
Inlet Air Cooling (TIAC) system. TIAC modular solution leaves the factory for startup; all that is left to carry out
is the connection to the existing utilities and the field piping connection to the
Gas turbines are mass flow engines, that is their power output is proportional
inlet air heat exchangers in the gas turbine filter house.
to the mass flow of air/fuel through the engine. Since the volumetric flow of
air through the engine is essentially constant, mass flow therefore changes
with the temperature of the air entering the compressor of the gas turbine.
When the ambient temperature is high, the power output and efficiency are
reduced. Thus, by cooling down the gas turbine inlet air ARANER improves the
turbine efficiency and increases its power output.
ARANER designed and fabricated the most appropriate TIAC system based on
different scenarios according to different site conditions. The TIAC plant was
based in a modular concept. In this concept, the main equipment is assembled
inside a module that can be easily transported. The assembly process is made
in a workshop with all of the required quality controls and testing, along with
precise cutting and machining tools. The finishing quality is much higher than
when the assemble works are made on-site.
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04 PROJECT EXECUTION
04
PROJECT EXECUTION
> ENGINEERING PHASE
Firstly, in order to complete every stage of the project in direct and continuous
contact with our client, we open a wide communication channel with our
clients to show, discuss and decide any points that may arise.
At ARANER, we consider that continuous communication between all the
parties is the key to understand perfectly the project requirements and to
optimize the tailor-made design.
> MANUFACTURING PHASE
Once the engineering and detailed design is completed, the manufacturing
process begins. ARANER manufacturers the specialized equipment:
• Industrial chillers adapted for Turbine Inlet Air Cooling operation
• Inlet Air Heat Exchangers
• Condensation Water Eliminators (Aradrop)
• Condensation Water Traps (Aratrap)
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04 PROJECT EXECUTION
04
PROJECT EXECUTION
Firstly, in order to complete every stage of the project in direct and continuous > MODULES PRE-ASSEMBLY PHASE
contact with our client, we open a wide communication channel with our
The modular concept was a major aspect of the solutions that made the
clients to show, discuss and decide any points that may arise.
project highly cost-effective.
At ARANER, we consider that continuous communication between all the
The main equipment was delivered to ARANER’s workshop in the United Arab
parties is the key to understand perfectly the project requirements and to
Emirates. In the workshop the pre-assembly of the following was undertaken:
optimize the tailor-made design.
• Chiller water connections are connected to piping
• Suction Pumps and outlets are connected to piping
• Expansion tanks are installed and connected to the water system
• All control cables are connected to junction boxes and tested
• All components are packaged in customized modules for easy
transportation and installation
The main advantage of the modular concept is that the final product is a
cooling plant ready to “Plug & Play”. After delivery to the site, the modules only
need to be connected to the utilities (water and power) and the chilled water
distribution network. Then, the plant is ready for commissioning.
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04 PROJECT EXECUTION
04
PROJECT EXECUTION
The second, but just as important advantage is the quality of the cooling plant. It is important to consider that the modules protect the equipment from outdoor
Doing the piping and steel fabrication in a workshop with a clean environment conditions so no mechanical building is required.
and the most advanced tools, will result to a higher quality than if the works are
A field erected mechanical building plus all the related civil works and utilities
performed at site.
(fire alarm, service water, etc) are major costs that are avoided with a modular
The consequence of these aforementioned points is a high quality system solution. Civil works are limited to the small foundations needed for the modules.
and a big decrease in project cost due to the on-site work being reduced.
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05 ARANER RESULTS
05
ARANER RESULTS
Turbine Inlet Air Cooling is a proven power augmentation technology. Gas The total extra power produced due to the TIAC system depends on the turbine
Turbines are designed for ISO Conditions (15 ºC and 60% RH), however they model. For each turbine model, the power output with and without TIAC has
lose around 20% – 40% of power when the ambient temperature is high. With been studied. The conclusion is that more than 149.16 MW of extra power are
TIAC systems, the air is typically cooled down to around 15 ºC so the gas turbine recovered thanks to TIAC system. This means that 21 % of extra power has been
will be working close to design conditions producing the maximum power. recovered with a very low capital cost.
Although 15 ºC is the industry standard design reference point, the exact
downstream design temperature for a TIAC system depends on individual
plant needs and economics.
TURBINE NUMBER OF POWER OUT POWER OUT WITH EXTRA POWER
PLANT
MODEL TURBINES WITHOUT TIAC (MW) TIAC (MW) (MW)
Plant 1 MS7001 EA 2 143.78 162.50 18.72
Plant 2 MS7001 FA 2 286.06 358.22 72.16
Plant 3 MS7001 FA 2 286.06 344.34 58.28
TOTAL 715.90 864.06 149.16
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DATA CENTERS
04 ARANER’S SOLUTION 05 ARANER RESULTS
05
ARANER RESULTS
As per the design conditions, the Inlet Air Flow is cooled from 50 ºC down to 20 ºC.
Although for this case the increase in power output is only 21% because of the project
requirements and parameters, for some cases and especially for aeroderivative gas
turbines the power recovered can be up to 40%.
As a result the project has surpassed Owner expectations not only because of the
extra power but also because of the efficiency increase that is achieved thanks to
the Turbine Inlet Air Cooling.
220
210
Chilled Conditions
200
190
149.16 MW EXTRA
POWER OUTPUT(MW)
POWER
180
170
160
Hot Conditions
150
140
130
120
5 10 15 20 25 30 35 40 45 50 55 60
INLET AIR TEMPERATURE (ºC)
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06 ONE-STEP FORWARD TO EXCELLENCE
06
ONE-STEP FORWARD TO EXCELLENCE
I+D HEAT EXCHANGERS COATING APPLICATION
As previously said, the GT area is the most important part of the power plant.
Particular care must be taken with all equipment installed in in the gas turbine
air stream, namely (the inlet air heat exchangers) must be properly designed
and selected. The materials and methods used during fabrication and the
procedures used to carry out the plant erection are critical to project success.
For this purpose, and because of the extreme site conditions found in the
plant location (proximity to the sea and surrounding industrial area), ARANER
developed a special and innovative coating based on phenolic resin which
guarantee long life operational service with no deterioration or corrosion.
Besides offering the highest protection to aggressive environments, this coating
did not affect the thermal conductivity of the heat exchangers, as would
normally happen with standard anti-corrosive paints.
In terms of field erection, ARANER gave full support to our client to minimize the
risk of damaging the equipment during installation. Such was the support that
ARANER dispatched their own engineers to the site and specialized technicians
shortening the original planned schedule.
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07 ABOUT TIAC
07
ABOUT TIAC
TURBINE INLET AIR COOLING · TIAC
Turbine Inlet Air Cooling (TIAC) is a group of technologies and techniques whose
objective is to cool down the intake air of the gas turbine and ultimately the
power output augmentation. This technology is widely used in warm climates
with high ambient temperatures that usually coincide with on-peak power
demand.
Gas turbine power plants are inherently designed to produce rated output and
operate more efficiently when the ambient (inlet) temperature is low. Lower
inlet air temperatures significantly increase power production and improve
power plant efficiency during periods of warm weather.
TIAC maximizes the power output and improves the energy efficiency of both
new and existing combustion turbine power plants for combined-cycle, simple-
cycle and co-generation.
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ABOUT
ARANER
ARANER Group of Companies constitutes an innovative and multi-disciplinary ARANER’s main strength lies in its manpower, with the team committed to
EPC business group, involving design, manufacturing, engineering, procurement aim and accept challenges that bring value in any of the fields where we
and construction activities. ARANER gets the know-how and experience of are present. ARANER face’s each project with the utmost professionalism. This
several pioneering and innovative companies from different areas of the world. allows our clients to be confident with our engineering and to be satisfied with
our solutions.
The company provides a wide range of products, solutions and professional
services to clients all across the world, where its leading-edge capabilities
cover several disciplines, mostly linked to Energy systems and Cooling and
Heating plants. Our goal is to create value for our stakeholders by meeting the
stated and implied needs of our customers, employees and the communities
where we exist and do business. We provide the best people working on the
most advanced engineering systems.
The company’s international structure, incorporated around ARANER Global
DMCC, as a Holding Company, and with subsidiaries in the most relevant
areas, allows the group to provide its solutions to all the markets where they
are required.
ARANER guarantees success in each project implementation. The company
develops pioneering and innovative solutions tailored to customer needs that
Contact ARANER >
go beyond the usual requirements of the industry, focused on high efficiency
and reliability.
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For continual development, ARANER
reserves the right to change specifications
or designs without notice.
©2021 ARANER
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