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Why Just

Replace when you


can Upgrade?

Retrofits and Upgrades to


Improve Efficiency & Reliability of
Your Gas Turbine System

A Global Power Company


Retrofits & Upgrades for
Gas Turbine Systems

Our Upgraded Designs Provide Contents Exhaust Diffuser Upgrades 4 Flex Seals and 14
Improved Efficiency and Reliability Exhaust Plenum Upgrades 6
HRSG Penetration Seals
Expansion Joints 15
over Original Equipment Exhaust Stack Retrofits and
Diverter Dampers
8
Gas Turbine and Auxiliary
Enclosure Replacements and
16
Stack Liners and Silencer Panels 9 Replacement Doors & Panels
Gas Turbine Inlet 10
When any of your Gas Turbine On-Time, On-Budget, On-Target Filter House Upgrades
Inlet Damper Systems 18

Auxiliary Systems need to be Replacement Filters 19


Bradens supervision of materials, procedures, and Engineered Skidded Systems 12
replaced, repaired or upgraded, personnel means single-source responsibility for SCR & CO Catalyst Systems 13
you shouldnt settle for Same As each construction event under contract. For turnkey for Simple Cycle Plants
projects, our approach minimizes erection time and
equipment. Take advantage of the costs and puts your plant on target to achieve peak
opportunity to upgrade with an power performance as quickly as possible.
improved design from Braden or

BETTER
Consolidated Fabricators! Our Unique Perspective
Our experience and background enables us to
The GT OEMs First Choice

than Before!
look at the big picture as we understand how all
Braden is uniquely qualified to provide an upgrade the subsystems work together to enhance the
to any of your Gas Turbine (also known as Combustion performance of your gas turbine. Our equipment
Turbine) Auxiliary Systems. As the preferred supplier recommendations are based on an understanding
to GT OEMs for over 50 years, chances are that we of your overall plant.
built your original system. As designs, specifications,
and construction techniques have evolved, Bradens
engineers have been at the forefront of improvements.
Today, we are capable of delivering gas turbine
auxiliaries that are demonstrably better than those
that came with your original system. An improved,
modern retrofit from Braden draws from our full array
of structural, mechanical, electrical, and acoustical
engineers to optimize your plant.

Before FS-3 filter house (no filtration) After FS-3 filter house (with mist eliminators, pre-filters, and final filters)
2 3
Exhaust Diffuser Upgrades

Our New Diffuser Designs Deliver


Longer Life and More Reliability
Design Enhancements Improve Services to Assist Diffuser Upgrades
Fatigue Life Rely on us to help with the whole process:
Our designs reduce first and second mode
Initial site survey
fundamental vibration frequencies to help deliver
Removal of old plenum, diffuser, and seals
improved fatigue life.
Installation of new equipment
Select components have increased material
thickness Testing of equipment with plant running

All welding is 100% penetration with root pass NDT


Diffuser is manufactured in a fixture to ensure Support Parts, Refurbishment
dimensional integrity and Reverse Engineering
Load tunnel insulation liner offers several We can supply all parts and equipment for
enhancements over the original equipment to your upgrade. When necessary, we can
prevent premature failures related to sagging reverse-engineer existing equipment that
insulation and vibration excitation of the needs to be upgraded.
load tunnel liner

Integrated Exhaust Systems


to Deliver Optimal Performance Other OEM designs are
We can provide a complete integrated system for a Upgrade Your Exhaust Plenum, available upon request
gas turbine exhaust, designed to operate efficiently Diffuser and Aft Wall Flex Seals
together. By combining a plenum with the diffuser Failure of your existing equipment could result
and hardware, we can assure a safer, more efficient in a forced shutdown, outage or damage to
and easier-to-operate system. instrumentation in the load tunnel and load
compartment. Ask us about a comprehensive Materials are selected to suit operating
approach to address these issues: conditions and can include:

L
 eakage of excess heat into the 300 or 400 Series stainless steels
Diffusers for all Frames 3, 5, 6, load compartment High Strength Low Alloy (HSLA) steels
7 and 9 GTs are available C
 racking of the exterior shell plate due Carbon steels
to high differential temperatures We maintain all welding capabilities.

4 5
Exhaust Plenum Upgrades

Modern Designs Improve Plenum Wing to Cowl Connection Cowl to Expansion Joint Connection

Safety & Efficiency 2 6


cowl gasket gasket
cowl
expansion joint transition expansion joint transition
cowl cowl
gasket gasket

4
Much has changed since your existing plenum was built. Today, our new
field
installed
liner and
field installed liner field installed liner
retrofit designs drastically reduce heat transfer, making the plenum/wing/
wing wing insulation
and insulation and insulation

cowl/expansion joint area safer, more efficient, reliable and easier to operate 3 4 Old Design: 800F New Design: 250F

and maintain. These retrofit designs can be applied to plenums of all sizes. Old Design: 685F New Design: 175F

Ask About Our Bullet-Proof Plenums! Frame 3, 5, 6, 7 & 9 Plenums


Designed for GTs that never come offline, these L
 atest designs allow the plenum and exhaust to 6
Wing to Plenum Plenum Sidewall to Cowl Connection
beefed-up plenums are the ultimate in reliability when remain in place during normal maintenance outages
Sidewall Connection 1
3 4

you just cant afford to be down. D


 esigned to reduce outage time which in turn 4
cowl cowl
reduces cost 1
Let Bradens Retrofit Engineers show you how these

3
2 gasket gasket

design improvements can help your system. A typical More robust flange design wing plenum
field installed
liner and
insulation
retrofit unit can be installed in one to two weeks Better thermal design and performance gasket

Old Design: 600F plenum


plenum
during a scheduled maintenance outage, with the R
 educed shell plate temperature to help extend
field installed
Old Design: 751F New Design: 260F
diffuser and turbine shaft in place. the plenum life cycle liner & insulation

U
 pgraded liner design helps protect the flex seal
5

4
Braden offers the manpower, equipment and
mounting bar from heat, distortion, separation of
experience to install at your site...or we can provide
the flanges, and bent flex seals wing plenum
detailed erection drawings and procedures for gasket 4
Upgraded corner trim at wing and cowl connection
your own crew. New Design: 300F
D
 esigned for all types of operation (base load to
Plenum Upgrades Can Include: cyclic load) 3
With hundreds in operation, we have perfected the
Plenum, wing, cowl, jacking port, radiation tubes,
internally lined exhaust plenum system, which took
flex seals and all necessary hardware Wing to Plenum Floor Connection Plenum Sidewall to Expansion Joint Connection
years of field research and inspections as well as
Reline kits are available! 3 5 field installed
liner & insulation
field installed
liner & insulation
visiting with our customers. Braden has developed field installed
liner & insulation
plenums for all OEM turbine sizes that are both
Integrated Exhaust Systems

4
3

4
3
easy to install and easy to dismantle for turbine
Braden and ConFab together can provide a maintenance. Our field splits are also fully internally wing
wing
plenum
plenum
transition plenum
transition
plenum gasket

6
complete integrated system for gas turbine lined and insulated to significantly reduce the gasket gasket
expansion joint
gasket
expansion joint

exhaust, designed to operate efficiently together. external shell plate temperatures. This equates to a Old Design: 698F New Design: 360F Old Design: 950F New Design: 410F
By combining a diffuser and hardware with the safe work environment and a product with a much
exhaust plenum, we can assure a safer, more longer life span.
efficient, and easier-to-operate system.

Plenums for SGTs and


V84 GTs are also available Liner system for field split, designed
for easy maintenance
6 7
Exhaust Stack Retrofits and Stack Liners and Silencer Panels
Diverter Dampers

Exhaust Stack Retrofits Improve Acoustics with


Have you changed your process and now have
different exhaust temperatures exiting the stack?
a New Stack Liner Design
Do you have corrosion from the elements? Or is
your stack just worn out?
Our modern stack designs feature a floating liner
Equipment that can be provided: system, a significant upgrade to previous methods.
Simple cycle stacks Thermal growth and stress are minimized by new,
Bypass stacks smaller liner sheets of 409SS material.
Ladders and platforms Braden has perfected a floating liner system that
Combined cycle stacks provides internal system stability in high turbulence,
Before After FS-5 exhaust
stack replacement high temperature environments such as F class
machines. Additionally, each design is evaluated Old liner style New liner style Hot spot identification
for internal pin spacing, pin size, liner plate thickness,

Diverter Dampers and clamping system positioning to ensure


system integrity.
Diverter Experience from the
Extreme World of Combined Cycle State-of-the-Art Acoustical Solutions
Braden has designed and manufactured diverter Our acoustical capabilities, backed up with extensive
dampers since 1985. The bulk of our diverter laboratory and field measurements, allow us to
9F toggle linkage mechanism GT13E2 diverter
experience is in combined cycle gas turbine power installed on a diverter damper develop state-of-the-art solutions for your noise
plants where extreme and sudden thermal changes control requirements. We have created designs to Exhaust silencer panel fabrication
necessitate thorough design foresight. The requirements for diverter design have multiplied dramatically meet noise requirements in the far field, near field,
due to increases in mass flow and exhaust gas temperatures stack exit, total system sound power, low frequency
Design Features combined with more operation cycles. The Braden design greatly emissions and more. Our silencer baffles have been Braden has more than 1,500 exhaust systems
Flexible Inconel seal elements reduces thermal stress, the cause of damage and leakage. extensively modeled and tested to survive the in operation worldwide, including exhaust
Whether you have the latest high-end gas turbine or a smaller harshest conditions created by modern turbines. systems for every major turbine OEM.
Toggle or pivot drive system operation
unit, we can ensure long-time reliability and performance. This includes our new baffle design optimized for
Thermal stress-free blade design
the fast turbine startups of F class machines.
Internal casing insulation F and H class technology
Delivery in one piece or split into sections as per High-reliability
transportation limits FEM analysis of all internal load / thermal stress-related
Hydraulic power units with HRSG protection mode Extensive experience
OEMs preferred choice
Over 250 diverter dampers built

Stack Damper Retrofits


Keep the elements outside with a counter-balanced, heat traced, Exhaust silencer panel replacement
durable, easy-to-install stack damper. These are ideal for high snowfall
locations and will help speed wintertime start-ups.

8 9
Gas Turbine Inlet
Filter House Upgrades

Braden is Widely Acclaimed by Implosion Door Retrofits


Gas Turbine OEMs as the World Leader in Avoid a turbine trip caused by extreme delta P with Bradens implosion door retrofits.

GT Inlet Cooling & Heating Technologies Our implosion doors are designed to mechanically open at pre-determined delta P to let
unfiltered air into the inlet of the gas turbine, bypassing the filters. Designs may include
mechanical switches that alert the control room when the door has been activated to
Our engineers have extensive experience and knowledge with providing innovative solutions on inlet
allow the operator to make the appropriate decision.
filter house systems based on specific environmental and end user requirements. We have produced
hundreds of top quality, cost-effective systems of filtration and auxiliary equipment that clean and
condition the air at low pressure drop for optimum power output while protecting the compressor

Inlet Cooling Systems


from damages by foreign objects.

Braden has extensive experience in providing media-based

Inlet Heating Systems evaporative coolers to both our OEM and Aftermarket customers.
Our system includes a total solution package comprising module
housings, cooler media and drift eliminators, interconnecting Before inlet cooling system
Braden has successfully designed and executed Braden can provide a system that your plant can
piping system, and system controls that can be integrated with
a variety of comprehensive inlet heating systems easily control to meet its specific temperature needs
your existing turbine control center or can be set up to operate
around the world to provide for anti-icing, from steam to air heat exchangers, water/glycol and
automatically using a PLC. Braden can offer solutions ranging from
turbine emissions control, or even increasing air coils, high and low pressure bleed air anti-icing
88% to 98% saturation effectiveness using higher face velocity
part load thermal efficiencyall based upon systems. Braden can also design and manufacture
media up to 750 feet per minute.
specific customer needs. heat exchanger skids to suit your needs.
After inlet cooling system

Filtration Systems Inlet Chilling Systems


Braden has a filtration system that can be
adapted to your existing gas turbine system, Braden can provide inlet chilling solutions that
whether it be a salt removal package or sub- can be added to your system to meet your peak
micron chemical dust removal. Our systems MW demand and obtain an air outlet temperature
include the following: as low as 45F. Inlet chillers
for GE 7FA,
Intake hoods for weather protection Braden engineers have years of experience in Brazos, TX
(e.g. rain or snow elimination) CFD and thermal modeling of inlet chilling systems
Mist elimination and coalescing filters and are equipped with the latest finite element
and volume analysis tools, heat transfer and
Static filter systems (pre-filters to
high efficiency final filters) thermodynamic modeling software to design an
integrated system that meets your requirements. Reverse return
Pulse filter systems (self-cleaning) piping for
Braden can provide the complete scope, chiller inlet chillers
Combination filtration systems housing, coils, condensate mitigation, transitions,
7FA barrier filter house with evaporative cooling
Salt removal package piping and controls.

Sub-micron particulate filtration

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Engineered Skidded Systems SCR & CO Catalyst Systems for
Simple Cycle Plants

Comprehensive 3D Modeling, Design and Put Our Experience to Work in Your


Engineering of Custom Systems Next NOx /CO Reduction Project
We excel at designing and manufacturing complex Extensive Experience Flow Management
mechanical, electrical and fluid systems such as fuel oil,
The combination of Braden SCR technology, coupled In the current environment of
fuel gas, lube oil, pump, or water and air handling. Our
with our international fabrication capabilities and high conversion efficiencies
fully-integrated Design and Engineering Department
exhaust structural design expertise, is a formula for and low ammonia slip levels,
will take your project from concept to finished
customer success. Our expertise includes the design proper flow distribution is
product, stressing design for manufacturability and
and supply of dozens of catalyst systems. We have absolutely essential to
ease of installation and maintenance thereby reducing
experience with over a thousand exhaust systems, catalyst system performance. CFD of flow distribution
lead times, outage schedule and overall cost.
including both stacks and silencers. In addition to We model all NOx and CO
Led by a dedicated Project Manager, our team offers exhaust structural engineering, we catalyst systems to verify proper flow distribution
a full range of Engineering Services including 3D Design SCR control systems through the catalyst, ensuring that specified reduction
design modeling, FEA analysis, CFD, complex load levels are met. Total system pressure drop is also a
Analyze flow by using state-of-the-art CFD modeling
calculations, ASME and PED design, drawings and key design consideration which is controlled by proper
Analyze structural decisions by using elaborate finite
prototyping. You can rely on our vast experience element analysis design of the ductwork and silencing systems.
with an extensive array of codes and validation/ Pressurization/vent skid
Meet customers noise criteria by using sophisticated
certification criteria to deliver a great solution. acoustic design programs
Create our own electrical and mechanical designs Ammonia Systems
Braden has extensive experience with both aqueous
and anhydrous ammonia systems and can supply
either type to meet your plant needs. Solutions that
can be provided are hot gas recirculation units or
electric heater atomization units.
Our usual scope of supply includes ammonia/ air
Structural loading
of pressurization/ dilution skid, ammonia piping and balancing header
vent skid and Ammonia Injection Grid (AIG). The skids come
completely shop-fabricated, insulated and wired for
fast and simple installation at the jobsite.
SCR system electric heater solution

Bradens capabilities include:


Silencing and
Fuel oil/water injection system
Ammonia vaporization skids
Thermal Stress Analysis
Noise control Noise attenuation is often critical to the design of
SCR/NOx Catalyst catalyst systems. Bradens in-house acoustic engineers
AIG design for low ammonia slip have designed many systems to meet challenging
CO catalyst
low-noise criteria.
Simple cycle GT exhaust flow management
Tempering air systems
CFD of heater box CFD
Ammonia storage & supply

12 13
Flex Seals and Expansion Joints
HRSG Penetration Seals

Step Up to a Superior Flex Seal Dont Just Replace the Belt...


Our flex seals are designed for the specific application, taking into Fix the Root Cause of the Belt Failure
consideration operating temperature, relative moments, and insulation
systems thereby resulting in optimized material selection, geometry,
and heat loss. Our Engineers Will Come to
Your Site and Do an EJ Analysis and
Engineer a Superior Product
Weve improved the OEM design of the flex seal
Braden will inspect and locate why your belt
to manage the thermal expansion in the turbine
failed and provide a comprehensive kit to address
exhaust. The Inconel seal flexes back and forth
the problemcomplete with belt, hardware,
every time the turbine is cycled, providing greater
studs and insulation.
protection for nearby equipment from exhaust leaks.
Improvements that can be made:
Full and partial kits available
Absorption of vibration/shock
Cost-effective solution Before burnt-out flex seals After 7F flex seal retrofit
Fix for minor misalignment of ductwork
Complete turnkey installation available
Expedited shipping available Improved design flex seal kits for: Corrosion resistance
Total kits including insulation available FS-5, FS-6, FS-7, 7F, 7FA, 7EA, FS-9, 9E, 9FA Can be designed for easy removal
during plant maintenance
Wider designs available (field trimmed) to
fit distorted units Temperature abatement

Our Most Common Kits Clamp bars bowing


up and bolts blown
FS-6: ASTM-A240 304SS and ASTM-A240 409SS materials out of alignment
7F: Inconel 718 and ASTM-A240 409SS materials from thermal shock
on old seals.
7EA: ASTM-A240 304SS material

Other OEM designs are also available Before After

Expansion joint analysis Expansion Joint Locations on


Custom-Engineered Factors that Influence EJ Design:
Gas Turbines:

Penetration Seals to Fit Your Application Belt material Frame material & design
Filter house
GT exhaust outlet
HRSG inlet
Exhaust stack
Insulation pillow L
 iner
Our HRSG penetration seals are designed for 3D model of upgraded
HRSG penetration seal Belt gap Insulation depth
the specific application, taking into consideration
Temperature Movements Only Need a Belt Section?
operating temperature, HRSG location (roof, Our typical HRSG penetration
If you have an area that is damaged or ripped,
seal kit includes: angle rings, Corrosive media P
 ressure
side walls, or floor), maximum expansion/contraction, expansion joint belt, insulation, Braden can evaluate and provide a belt section
and vibration or lateral movements. No matter what clamping bars, bolts, Our engineers will select an EJ design that
washers and nuts, angle clips, that can be spliced to your existing material.
configuration, we can engineer an HRSG penetration and installation drawings will meet or exceed your expectations. This saves on the cost of replacing the entire
seal to fit your application! expansion joint belt.

14 15
Gas Turbine and Auxiliary Enclosure Replacements
and Replacement Doors & Panels

Ask the Upgrade Experts for a GT SmartDoor Products:


Highly Functional Enclosure to Better Function, Easier to Order, Attractive Pricing
Replace What Youve Got
Repairing or replacing damaged, corroded or Easy to Order, Easier to Install
worn-out gas turbine enclosure doors or panels has
No OEM door or panel drawings needed!
traditionally been a frustrating, time-consuming
and expensive chore. Due to the non-standardized, Just fill in our easy-to-use standardized form
welded fabrications, each old door or panel with the required dimensionswell ask for
required its own engineering drawing and complex just whats needed.
manufacturing sequence and factory assembly that Bolted plug & play installation...
eliminated any opportunity for on-site modification. no welding required.
GT SmartDoor products represent a whole new
approach to enclosure maintenance: a better door or
panel, thats easy to order and can be re-insulated
or re-gasketed on-site to maintain thermal and
acoustic performance.
Formed plate door exterior eliminates
Acoustic
enclosure - welded construction the only welding is
auxiliary equipment for stud-welded attachments
Tadpole gasket is firmly secured by clamping
Chances are, your enclosures never really got a lot of
bar (not glued), allowing precise control of
thought when they were first built. Understandably, Panic push
pressure on seal to make a seamless door seal
the equipment inside got first priority. As your knob and
Bolted design allows easy re-insulation or panic bar
installation ages, however, there is no reason to settle available.
for a same as design when the enclosure is replaced. repair on-site

Let us show you how much a well-design solution Standardized insulation tubes
can help your operation. Acoustic enclosure - auxiliary equipment Improved hardware, including an exclusive
latch for doors that open with handles on Exclusive
same post for suicide doors latch design.
Hardware is available separately.
Multiple construction material
options available, including
stainless steel

Steam turbine enclosure W501F GT enclosure Generator enclosure Exciter enclosure


Need customization?
We can add windows, scanner
boxes and vents to any door.

Before After

16 17
Inlet Damper Systems Replacement Filters

Solutions for Moisture-Rich and ExCel Pulsed GT Inlet Filters


Cold Environments
ExCel Premier Web: The Best Balance
of Performance and Value
Moisture-rich environments can cause unnecessary corrosion and erosion to internal components on
Gas Turbine (GT) inlet and compressor components. Blades, vanes, and other components can see ExCel premier web filters are F9, MERV 15 rated,
moisture pitting and staining leading to decreased efficiency. Another problem in cold environments is (efficiencies >70% @ 0.4 m) meeting EN779-2012.
that the HRSG cannot retain heat from escaping without closing off the inlet system. Their custom engineered 100% synthetic non-woven
media technology provides: ExCel Filters are
With that in mind, Braden designed its inlet damper systems to deliver conditioned air between Available for All
Optimized design for the most challenging
the filter house and gas turbine for typical use when the GT is shut down or is on turning gear for an Inlet Systems
pulse jet cleaning applications
extended period of time. Our system is built to the following codes: ASME, ASTM, AWS, NFPA,
NRTL cert., NEC, IEC, and NEMA. 100% mechanical filtration technology (no
special fabric treatments that quickly wear off)
Surface filtration technology
Hydrophobic performance with maximum
Inlet Damper Door Dehumidifier Skid wet strength
Durable construction using mechanical
glue bead pleat separation

Outstanding Performance for


Base Load and Peakers
Switch to ExCel premier web filters to stabilize
pressure drop and improve filtration efficiencies
while avoiding the ultra premium pricing of
triple layer filters.
Prefilters &
Coalescing Filters
Braden offers a wide range
of prefilters and coalescer/
Used primarily to seal off the GT internals Used in conjunction with the inlet damper prefilters for a variety of

AIR FLOW
from the outside environment. door to provide dehumidified air to the GT airflow conditions, including
re-usable plastic frames for
Natural air convection from stack draft effect internals (a heater skid can also be provided). high moisture applications.
causes air to continue to flow through the Technical Design:
inlet, GT, and exhaust duct when shut down
or on turning gear.
C
 onnected to inlet system by
TriCel Barrier

Final Filters
interconnecting piping
Technical Design: P
 LC-controlled safety system to prevent
Minimal leakage design fire, component damage, and if there is Bradens TriCel high-efficiency
any blockage in the system barrier filter is specifically
Stainless steel or carbon steel construction ExCel premier web filters Other filters use depth loading designed for gas turbine air
30-year design life employ surface loading media which traps particulate intake applications. Using
30-year design life technology to provide longer deep into the media, making the latest manufacturing
life and easier pulsed cleaning cleaning difficult techniques in filter media and
pleating, the TriCel filter provides high volumetric
air flow with extremely low pressure drop.

18 19
Turnkey The Global
Power Companies
Solutions. Leaders in Providing
Custom-Engineered
Auxiliary Equipment
Integrated System and Support Services
for the Global Power
Knowledge. Generation Industry

Braden Manufacturing, LLC


Global leader in design, manufacture
and installation of auxiliary equipment
for gas turbines

Consolidated Fabricators, Inc.


Design and manufacturing of complex
mechanical, electrical and fluid systems

Hetsco, Inc.
Leading global provider of brazed
aluminum heat exchanger repair,
maintenance and safety services to
5199 North Mingo Road the industrial gas, liquified natural gas
Tulsa, OK 74117 USA
and petrochemical industries
Tel: 918-272-5371
Fax: 918-272-7414 Koontz-Wagner Custom
E-mail: sales@braden.com Controls Holdings, LLC
www.braden.com Design, construction and electrical
integration of packaged control rooms

TOG Manufacturing Company, Inc.


Manufacturer of precision machined
parts for gas and steam turbines
A Global Power Company

17 St. Mark Street Williams Industrial


Fairfax Industrial Park Services Group, LLC
Auburn, MA 01501 USA General and specialty construction,
Tel: 508-797-8000 maintenance and modification,
Fax: 508-832-7369 plant management and support
Email: sales@consolidatedfabricators.com services for nuclear, hydro and
www.consolidatedfabricators.com fossil power generation

www.globalpower.com
We design and fabricate to numerous certifications,
including those listed here and many others.

2
 016 Global Power Equipment The Global Power logo design is a registered trademark of Global Power
Equipment Group, Inc. The Braden logo design is a registered trademark of Braden Manufacturing, LLC.
ExCel and TriCel are registered trademarks of Braden Manufacturing, LLC. All rights reserved.