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
Improved Efficiency and Reliability
over Original Equipment
When any of your Gas Turbine
Auxiliary Systems need to be
replaced, repaired or upgraded,
you shouldnt settle for Same As
equipment. Take advantage of the
opportunity to upgrade with an
improved design from Braden or
Consolidated Fabricators!
The GT OEMs First Choice
Braden is uniquely qualified to provide an upgrade
to any of your Gas Turbine (also known as Combustion
Turbine) Auxiliary Systems. As the preferred supplier
to GT OEMs for over 50 years, chances are that we
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.
2 3
Contents Exhaust Diffuser Upgrades 4 Flex Seals and 14
Exhaust Plenum Upgrades 6
HRSG Penetration Seals
Expansion Joints 15
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
On-Time, On-Budget, On-Target Filter House Upgrades
Inlet Damper Systems 18
Replacement Filters 19
Bradens supervision of materials, procedures, and Engineered Skidded Systems 12
personnel means single-source responsibility for SCR & CO Catalyst Systems 13
each construction event under contract. For turnkey for Simple Cycle Plants
projects, our approach minimizes erection time and
costs and puts your plant on target to achieve peak
power performance as quickly as possible.
BETTER
Our Unique Perspective
Our experience and background enables us to
than Before!
look at the big picture as we understand how all
the subsystems work together to enhance the
performance of your gas turbine. Our equipment
recommendations are based on an understanding
of your overall plant.
Before FS-3 filter house (no filtration) After FS-3 filter house (with mist eliminators, pre-filters, and final filters)
 Exhaust Diffuser Upgrades
Our New Diffuser Designs Deliver
Longer Life and More Reliability
Design Enhancements Improve
Fatigue Life
Our designs reduce first and second mode
fundamental vibration frequencies to help deliver
improved fatigue life.
Select components have increased material
thickness
All welding is 100% penetration with root pass NDT
Diffuser is manufactured in a fixture to ensure
dimensional integrity
Load tunnel insulation liner offers several
enhancements over the original equipment to
prevent premature failures related to sagging
insulation and vibration excitation of the
load tunnel liner
Integrated Exhaust Systems
to Deliver Optimal Performance
We can provide a complete integrated system for a
gas turbine exhaust, designed to operate efficiently
together. By combining a plenum with the diffuser
and hardware, we can assure a safer, more efficient
and easier-to-operate system.
Diffusers for all Frames 3, 5, 6,
7 and 9 GTs are available
4 5
Services to Assist Diffuser Upgrades
Rely on us to help with the whole process:
Initial site survey
Removal of old plenum, diffuser, and seals
Installation of new equipment
Testing of equipment with plant running
Support Parts, Refurbishment
and Reverse Engineering
We can supply all parts and equipment for
your upgrade. When necessary, we can
reverse-engineer existing equipment that
needs to be upgraded.
Other OEM designs are
Upgrade Your Exhaust Plenum, available upon request
Diffuser and Aft Wall Flex Seals
Failure of your existing equipment could result
in a forced shutdown, outage or damage to
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
load compartment High Strength Low Alloy (HSLA) steels
C
 racking of the exterior shell plate due Carbon steels
to high differential temperatures We maintain all welding capabilities.
 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
Diverter Dampers
Exhaust Stack Retrofits
Have you changed your process and now have
different exhaust temperatures exiting the stack?
Do you have corrosion from the elements? Or is
your stack just worn out?
Equipment that can be provided:
Simple cycle stacks
Bypass stacks
Ladders and platforms
Combined cycle stacks
Diverter Dampers
Diverter Experience from the
Extreme World of Combined Cycle
Braden has designed and manufactured diverter
dampers since 1985. The bulk of our diverter
experience is in combined cycle gas turbine power
plants where extreme and sudden thermal changes
necessitate thorough design foresight.
Design Features
Flexible Inconel seal elements
Toggle or pivot drive system operation
Thermal stress-free blade design
Internal casing insulation
Delivery in one piece or split into sections as per
transportation limits
Hydraulic power units with HRSG protection mode
Stack Damper Retrofits
Keep the elements outside with a counter-balanced, heat traced,
durable, easy-to-install stack damper. These are ideal for high snowfall
locations and will help speed wintertime start-ups.
8 9
Stack Liners and Silencer Panels
Improve Acoustics with
a New Stack Liner Design
Our modern stack designs feature a floating liner
system, a significant upgrade to previous methods.
Thermal growth and stress are minimized by new,
smaller liner sheets of 409SS material.
Braden has perfected a floating liner system that
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,
and clamping system positioning to ensure
system integrity.
State-of-the-Art Acoustical Solutions
Our acoustical capabilities, backed up with extensive
laboratory and field measurements, allow us to
9F toggle linkage mechanism GT13E2 diverter
installed on a diverter damper develop state-of-the-art solutions for your noise
control requirements. We have created designs to Exhaust silencer panel fabrication
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
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
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.
unit, we can ensure long-time reliability and performance. This includes our new baffle design optimized for
the fast turbine startups of F class machines.
F and H class technology
High-reliability
FEM analysis of all internal load / thermal stress-related
Extensive experience
OEMs preferred choice
Over 250 diverter dampers built
Exhaust silencer panel replacement
 Gas Turbine Inlet
Filter House Upgrades
Braden is Widely Acclaimed by
Gas Turbine OEMs as the World Leader in
GT Inlet Cooling & Heating Technologies
Our engineers have extensive experience and knowledge with providing innovative solutions on inlet
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
from damages by foreign objects.
Inlet Heating Systems
Braden has successfully designed and executed
a variety of comprehensive inlet heating systems
around the world to provide for anti-icing,
turbine emissions control, or even increasing
part load thermal efficiencyall based upon
specific customer needs.
Filtration Systems
Braden has a filtration system that can be
adapted to your existing gas turbine system,
whether it be a salt removal package or sub-
micron chemical dust removal. Our systems
include the following:
Intake hoods for weather protection
(e.g. rain or snow elimination)
Mist elimination and coalescing filters
Static filter systems (pre-filters to
high efficiency final filters)
Pulse filter systems (self-cleaning)
Combination filtration systems
7FA barrier filter house with evaporative cooling
Salt removal package
Sub-micron particulate filtration
10
Implosion Door Retrofits
Avoid a turbine trip caused by extreme delta P with Bradens implosion door retrofits.
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
allow the operator to make the appropriate decision.
Inlet Cooling Systems
Braden has extensive experience in providing media-based
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 can provide a system that your plant can
piping system, and system controls that can be integrated with
easily control to meet its specific temperature needs
your existing turbine control center or can be set up to operate
from steam to air heat exchangers, water/glycol and
automatically using a PLC. Braden can offer solutions ranging from
air coils, high and low pressure bleed air anti-icing
88% to 98% saturation effectiveness using higher face velocity
systems. Braden can also design and manufacture
media up to 750 feet per minute.
heat exchanger skids to suit your needs.
After inlet cooling system
Inlet Chilling Systems
Braden can provide inlet chilling solutions that
can be added to your system to meet your peak
MW demand and obtain an air outlet temperature
as low as 45F. Inlet chillers
for GE 7FA,
Braden engineers have years of experience in Brazos, TX
CFD and thermal modeling of inlet chilling systems
and are equipped with the latest finite element
and volume analysis tools, heat transfer and
thermodynamic modeling software to design an
integrated system that meets your requirements. Reverse return
piping for
Braden can provide the complete scope, chiller inlet chillers
housing, coils, condensate mitigation, transitions,
piping and controls.
11
 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
We excel at designing and manufacturing complex
mechanical, electrical and fluid systems such as fuel oil,
fuel gas, lube oil, pump, or water and air handling. Our
fully-integrated Design and Engineering Department
will take your project from concept to finished
product, stressing design for manufacturability and
ease of installation and maintenance thereby reducing
lead times, outage schedule and overall cost.
Led by a dedicated Project Manager, our team offers
a full range of Engineering Services including 3D
design modeling, FEA analysis, CFD, complex load
calculations, ASME and PED design, drawings and
prototyping. You can rely on our vast experience
with an extensive array of codes and validation/
certification criteria to deliver a great solution.
Next NOx /CO Reduction Project
Extensive Experience
The combination of Braden SCR technology, coupled
with our international fabrication capabilities and
exhaust structural design expertise, is a formula for
customer success. Our expertise includes the design
and supply of dozens of catalyst systems. We have
experience with over a thousand exhaust systems,
including both stacks and silencers. In addition to
exhaust structural engineering, we
Design SCR control systems
Analyze flow by using state-of-the-art CFD modeling
Analyze structural decisions by using elaborate finite
element analysis
Pressurization/vent skid
Meet customers noise criteria by using sophisticated
acoustic design programs
Create our own electrical and mechanical designs
Structural loading
of pressurization/
vent skid
SCR system electric heater solution
Flow Management
In the current environment of
high conversion efficiencies
and low ammonia slip levels,
proper flow distribution is
absolutely essential to
catalyst system performance. CFD of flow distribution
We model all NOx and CO
catalyst systems to verify proper flow distribution
through the catalyst, ensuring that specified reduction
levels are met. Total system pressure drop is also a
key design consideration which is controlled by proper
design of the ductwork and silencing systems.
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
dilution skid, ammonia piping and balancing header
and Ammonia Injection Grid (AIG). The skids come
completely shop-fabricated, insulated and wired for
fast and simple installation at the jobsite.

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.