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INTRODUCTION
Based on new challenges in the fossil fuel industry, combined cycle technology is a leading solution
in improving efficiency and reducing emissions. Many organizations have considered or are
considering the placement and development of new combined cycle plants. This thesis will explain
how these plants operate and what the advantages are of moving into the combined cycle arena[1].
The gas and steam turbines are the greatest means to generate mechanical power. Both gas and steam
turbines have been successfully working in large scale to generate the electricity, whereas gas turbine
ensures superior thermal efficiency as compared to steam turbine. Different means have been
employed by a lot of researchers to get better thermal efficiency of the turbines, particularly the gas
turbine. One of the means is to increase the gas-turbine inlet temperatures and decrease the
compressor inlet air temperatures, this mean increase the peak cycle temperature ratio. As a
consequence of cycle peak temperature ratio, higher exhaust gases temperature results, which means
increase the energy loss at the stack[2].
We focused on increase the efficiency of CCGT power plant system utilizing the Brayton Cycle gas
turbine and Rankine Cycle steam turbine with air and water as working fluids achieve efficient,
reliable, and economic power generation. Current commercially available generation CCGT power
plants achieve total thermal efficiency typically in the 50- 60% Lower Heating Value range. Further
development of simple cycle gas turbine, metal surface cooling technology, and high temperature
bleed materials show promise for near term generation power for CCGT power plants capable of
reaching more than 60% plant thermal efficiency. Additional the development in gas-turbine
technology, as well as increases in steam-turbine cycle temperature and pressure, HRSG stage design
enhancement, is expected to achieve further combined-cycle gas-turbine power plants efficiency
improvement. The combination of the gas-turbine Brayton Cycle and the steam turbine power plant
Rankine Cycle complement each other to form efficient CCGT power plants. The Brayton Cycle has
high source temperature and rejects heat at a temperature that is conveniently used as the energy
source for the Rankine Cycle plant. The most commonly used working fluid for combined cycle gas
turbine power plants are air and steam.
Improving the combined cycle efficiency has always been an important objective of any cycle
analysis. The gas turbine power plant despite its low efficiency is a very versatile unit because of its
simplicity and low cost. The advantages are even greater if the energy of the exhaust gas can be
effectively used. Because of high air fuel ratio, exhaust gas has a high portion of oxygen and further
combustion can also be carried out. One convenient approach is to combine two different cycles to
form a new power generating cycle.One of the popular schemes is the combination of Brayton cycle
and Rankine cycle. Such a combination is called the combined cycle power plant[3].
During the last two decades a number of alternative combined cycle concepts have been evolved.
The simplest of course consists of simple gas turbine coupled with a single pressure bottoming cycle.
However, in this concept, the waste heat utilization is not very effective both in terms of energy and
energy. This can be substantially held by employing dual pressure or triple pressure bottoming cycle
with or without reheating. In selective cases the combined cycle using supplementary firing in a
waste HRSG boiler is also used with advantage[4].
For large-scale power generation, a typical set would be a 270 MW gas turbine coupled to a 130 MW
steam turbine giving 400 MW. A typical power station might consist of between 1 and 6 such
sets.Plant size is important in the cost of the plant. The larger plant sizes benefit from economies of
scale (lower initial cost per kilowatt) and improved efficiency[5].
A single shaft combined cycle plant comprises a gas turbine and a steam turbine driving a common
generator. In a multi-shaft combined cycle plant, each gas turbine and each steam turbine has its own
generator. The single shaft design provides slightly less initial cost and slightly better efficiency than
if the gas and steam turbines had their own generators. The multi-shaft design enables two or more
gas turbines to operate in conjunction with a single steam turbine, which can be more economical
than a number of single shaft units[5].
The primary disadvantage of single shaft combined cycle power plants is that the number of steam
turbines, condensers and condensate systems - and perhaps the number of cooling towers and
circulating water systems - increases to match the number of gas turbines. For a multi-shaft
combined cycle power plant there is only one steam turbine, condenser and the rest of the heat sink
for up to three gas turbines; only their size increases. Having only one large steam turbine and heat
sink results in low cost because of economies of scale. A larger steam turbine also allows the use of
higher pressures and results in a more efficient steam cycle. Thus the overall plant size and the
associated number of gas turbines required have a major impact on whether a single shaft combined
cycle power plant or a multiple shaft combined cycle power plant is more economical[5].
Gas turbines of about 150 MW size are already in operation manufactured by at least four separate
groups - General Electric and its licensees, Alstom, Siemens, and Westinghouse/Mitsubishi. These
groups are also developing, testing and/or marketing gas turbine sizes of about 200 MW. Combined
cycle units are made up of one or more such gas turbines, each with a waste heat steam generator
arranged to supply steam to a single steam turbine, thus forming a combined cycle block or unit.
Typical Combined cycle block sizes offered by three major manufacturers (Alstom, General Electric
and Siemens) are roughly in the range of 50 MW to 500 MW and costs are about $600/kW[5].
The turbines used in Combined Cycle Plants are commonly fueled with natural gas. Global natural
gas reserves were expected to be fully consumed by 2070,[2] however the improvement in shale
gas extraction through hydraulic fracturing has increased gas supplies and reserves dramatically.
Because of this fact, it is becoming the fuel of choice for an increasing amount of private investors
and consumers because it is more versatile than coal or oil and can be used in 90% of energy
applications. Chile which once depended on hydro-power for 70% of its electricity supply, is now
boosting its gas supplies to reduce reliance on its drought afflicted hydro dams. Similarly China is
tapping its gas reserves to reduce reliance on coal, which is currently burned to generate 80% of the
countrys electricity supply[5].
Where the extension of a gas pipeline is impractical or cannot be economically justified, electricity
needs in remote areas can be met with small-scale Combined Cycle Plants, using renewable fuels.
Instead of natural gas, Combined Cycle Plants can be filled with biogas derived from agricultural and
forestry waste, which is often readily available in rural areas[5].
The combined-cycle system includes single-shaft and multi-shaft configurations. The single-shaft
system consists of one gas turbine, one steam turbine, one generator and one Heat Recovery Steam
Generator (HRSG), with the gas turbine and steam turbine coupled to the single generator in a
tandem arrangement on a single shaft. Key advantages of the single-shaft arrangement are operating
simplicity, smaller footprint, and lower startup cost. Single-shaft arrangements, however, will tend to
have less flexibility and equivalent reliability than multi-shaft blocks. Additional operational
flexibility is provided with a steam turbine which can be disconnected, using a synchro-self-shifting
(SSS) Clutch,for start up or for simple cycle operation of the gas turbine[5].
Multi-shaft systems have one or more gas turbine-generators and HRSGs that supply steam through a
common header to a separate single steam turbine-generator. In terms of overall investment a multishaft system is about 5% higher in costs[5].
The efficiency of heat engines and power stations should be stated HHV ( Higher Heating Value) or
LHV (Lower Heating Value) to exclude, or include respectively the heat and power that can be
obtained from condensing the flue gas, and Gross output at the generator terminals or Net Output at
the power station fence are being considered[5].
In general in service Combined Cycle efficiencies are over 50 percent on a lower heating value and
Gross Output basis. Most combined cycle units, especially the larger units, have peak, steady state
efficiencies of 55 to 59%.
By combining both gas and steam cycles, high input temperatures and low output temperatures can
be achieved. The efficiency of the cycles add, because they are powered by the same fuel source. So,
a combined cycle plant has a thermodynamic cycle that operates between the gas-turbine's high firing
temperature and the waste heat temperature from the condensers of the steam cycle. This large range
means that the Carnot efficiency of the cycle is high. The actual efficiency, while lower than this, is
still higher than that of either plant on its own.[5] The actual efficiency achievable is a complex
area[6].
The electric efficiency of a combined cycle power station, if calculated as electric energy produced
as a percent of the lower heating value of the fuel consumed, may be as high as 58 percent when
operating new, i.e. unaged, and at continuous output which are ideal conditions. As with single cycle
thermal units, combined cycle units may also deliver low temperature heat energy for industrial
processes, district heating and other uses. This is called cogeneration and such power plants are often
referred to as a Combined Heat and Power plant[6].
The efficiency of CCGT and GT can be boosted by pre-cooling combustion air. This is practiced in
hot climates and also has the effect of increasing power output. This is achieved by evaporative
cooling of water using a moist matrix placed in front of the turbine, or by using Ice storage air
conditioning. The latter has the advantage of greater improvements due to the lower temperatures
available. Furthermore, ice storage can be used as a means of load control or load shifting since ice
can be made during periods of low power demand and, potentially in the future the anticipated high
availability of other resources such as renewables during certain periods[6].
In Pakistan, WAPDA operates the majority of thermal power plants, with over 5000 MW of installed
capacity in its control. The Guddu plant is the largest plant with a capacity of 1650 MW. In recent
years, growth in Pakistans thermal power generation has come primarily from new independent
power producer (IPPs), some of which have been funded by foreign investor. The two largest IPPs in
Pakistan are KotAddu (1600MW) and Hub Power (1292MW)[7].
Nandipur Power Project is an under construction combined cycle thermal power plant located at
Nandipur near Gujranwala, in the province of Punjab. Its One Gas Turbine of 95.4 MW capacity has
in working from May 2014.The project is estimated to be completed by December 2014. Upon
completion, the project will generate 425 MW's of electricity. The estimated cost of the project is Rs.
57.38 billion. Being constructed by the China Dongfang Electric Corporation, NESPAK is
Consultant and Executing Agency is NPGCL. This Project is sponsored by Ministry of Water &
Power Pakistan[8].
The fuel used in this power plant is HSD and HSFO but we can used Natural Gas to increase the
efficiency of the plant. There are ten tank for fuel storage, eight for HSFO and two for HSD.
Capacity of each tank is 10,000 M.Ton. The total Oil storage capacity of Nandipur Power Plant is
100,000 M.Ton. For storage of fuel, two tank used for HSD and eight tanks used for HSFO. HSFO is
treated here by centrifugal type Separators. The capacity of fuel oil treatment plant (FOTP) is 120
M.Ton/hr while required capacity is 90 M.Ton/hr. The treated HSFO stored in four tanks while four
HSFO tanks are untreated[8].
The axial airflow compressor of 17 stages is used to compress the air. The outlet temperature
reaches 355C and Compression ratio 12.65.Then fuel combust in combustion chamber. The turbine
inlet temperature typically reaches roughly 1200C. In the turbine, these gases are then converted to
work, which drives the turbine connected to a generator for electricity production. Each gas turbine
has a design power output of 95.4 MW and design efficiency in the order of 20-25%. Steam Turbine
cycle. Exhaust gases from the gas turbines remain at very high temperatures (500C).The CCGT
process recycles the remaining energy in the exhaust gas to drive a secondary or bottoming cycle[8].
This is achieved by piping the exhaust gas through a heat recovery steam generator (HRSG) system
to heat treated Canal water for the generation of steam. Under normal operations, 40500ton/hr of raw
water is drawn from the Upper Chenab Canal and undergoes treatment including sedimentation,
primary and secondary filtration with activated carbon, and demineralization. The purified water is
then passed through the HRSG system and converted into steam by utilizing the heat in the topping
cycle exhaust gas. The steam from both HRSGs is forced through the throttle to drive a single steam
turbine connected to a generator for electricity production. The steam turbine has a design power
output of 138 MW and efficiency in the order of 34%.After the steam expands through the turbine, it
is piped through a heat exchanger to convert the steam back into water (condensate). This condensate
is then returned to the HRSG through high-pressure feed pumps for reuse[8].
In order to convert the steam expelled from the turbine back into a condensate, heat must be
extracted. This is achieved using a once-through cooling water cycle. The source of the cooling water
is the Upper Chenab Canal or underground water. Two cooling water pumps with a combined design
capacity of 40500 ton/hr then draw water below the surface or from canal and pump the cooling
water into the heat exchanger[8].
The external surface of the heat exchanger is exposed to pumped cooling water, while the expelled
steam flows within. This transfers heat energy from the steam flowing inside the pipes to the cooling
water outside, cooling the steam back to water[8].
The cooling water exits the heat exchanger at a higher temperature than the inlet and is circulated to
an underground tank before being discharged back to the Canal via an open channel. The increase in
temperature (between the inlet and the discharge) can be controlled by altering the pumped flow rate
by partially opening or closing the globe valves immediately downstream of the cooling water
pumps. A higher flow rate will result in lower discharge temperature for the cooling water but will
require greater fuel consumption at the cooling water pumps. Under normal operating conditions the
valves are 70%80% open, with total energy consumption in the cooling water pumps of 4,114
kilowatts [8].
The net output of this CCPP is 411 MW with efficiency of 46.5%.The total fuel consumption is 2500
Ton/day. We can increase the efficiency of this power plant by using Natural Gas instead of HSFO
and HSD fuel. In this way one Gas Turbine produced 115 MW instead of 95.4MW while Gas
Turbine capacity increase from 138 MW to 180 MW[6].
6
In this thesis we discuss the basic components of a combined cycle power plant and how they work
together to produce energy. The basic concepts of temperature, work, and heat in power plant
operation and basics of fuel combustion, how fuels are prepared and combusted in a combustion
turbine. Discuss basic components of a heat recovery steam generator and steam turbine how they
work together to produce mechanical energy. Operation and maintenance of a combined cycle plant.
Objectives:
Improvement in efficiency
CHAPTER 02
LITERATURE REVIEW
The first gas turbine installed in an electric utility in the United States was applied in a combined
cycle. This was a 3.5 MW gas turbine that used the energy from the exhaust gas to heat feed water
for a 35 MW conventional steam unit. This system entered service in June 1949, and a similar system
was added to this station in 1952. The heat recovery economizers applied in these systems used bare
tubes, as was typical of heat exchangers in combined-cycle systems installed prior to 1959.
In 1950 and early 1960, most combined-cycle power generation systems installed included
conventional-fired boilers. These systems were basically adaptations of conventional steam plants
with the gas turbine exhaust gas serving as combustion air for the boiler. The efficiency of this
type of combined cycle was approximately 5-6% higher than that of a similar conventional steam
plant. These systems could economically utilize bare tubes in the boiler because of the high mean
temperature difference between the combustion products and the water/steam.
The repowering of steam power plants with gas turbine generators and HRSGs is still attractive in
many applications today as evidenced by the recent Colorado Public Service, Fort St. Vrain
installation, which was placed in commercial operation in 1999.
Equipment that made it economically feasible to weld continuous spiral fins to tubes was introduced
to boiler manufacturers in 1958. Heat recovery combined cycles, using the sensible heat in the gas
turbine exhaust gas, were made feasible by the enhanced gas-side heat transfer using finned tubes.
Combined-cycle systems with finned tube boilers entered service in 1959.
During the 1960s the application of the heat recovery type of combined-cycle systems became
more prevalent. Its initial application was in power and heat applications where its power-to-heat
ratio was more favorable. Also, a small number of the heat recovery type combined cycles were
installed in utility power generation applications during the 1960s. Application of these systems in
the 1970s and 1980s established the heat recovery feed water heating combined-cycle as a mature
technology for base load and mid-range service.
The requirements for stack gas NOx emission control was initially legislated during the late 1970s.
The first systems utilized gas turbine water or steam injection to meet new source performance
8
standards of 75 ppmvd at 15% oxygen with efficiency and fuel-bound nitrogen adjustments.
Combined-cycle plants utilized steam from the steam cycle for NOx control because this had the
least impact on plant efficiency. As emission requirements became more stringent, it was necessary
to apply SCR to argument NOx abatement (TEPCO Groups I and II). Application of SCR systems
became common in Japan and in the USA in the mid-1980s.
The first and second generation combined cycles were configured using gas turbine designs that
were optimized for simple-cycle output and efficiency.
Specific power (i.e., output per pound of air flow) is important since the higher the value, the
smaller the gas turbine required for design power output. The importance of thermal efficiency is
obvious since it directly impacts the operating fuel cost.
1. Where simple-cycle efficiency is the
goal, high pressure ratio is desirable
2. Where combined-cycle efficiency is the
objective, more modest pressure ratios are selected.
3. Firing temperature has a greater
impact on combined-cycle efficiency than simple-cycle efficiency.
Fuel price escalation in the 1970s and 1980s further increased the need for more efficient power
plants for base- and mid-range service. This led to gas turbine designs in the late 1980s that were
optimized specifically for combined- cycle .
The GE "F" Technology gas turbine designed in the 1980s, with pressure ratio of about 14:1 and
2400F firing temperature was the result of a design effort aimed at optimization for combinedcycle peak efficiency rather than simple- cycle peak efficiency
The fleet leader "F" Technology gas turbine entered commercial operation in 1990 in a combinedcycle installation at the Virginia Power Chesterfield site and launched the third generation of
combined-cycle systems.
Further gas turbine materials development and hot gas path cooling technology advances, as well
as higher temperature and pressure steam cycles, will continue the trend for more efficient
combined-cycle systems in the future.
Gas turbines installed in the first, second and third generation combined-cycle plants are configured
9
with open-loop cooling of the turbine hot gas path and cooling air supplied from the compressor.
Hot gas path components are in large part cooled by film cooling. As a result, there is significant
exhaust gas temperature drop across the first stage nozzle, and significant "chargeable air" required
to cool down the steam turbine stages. The drop in exhaust gas temperature across the first stage
nozzle and the increase in chargeable cooling loss due to increases in turbine firing temperature
may diminish efficiency gains to the point of being uneconomical. For this reason, the fourth
generation plants with "H" Technology gas turbines will be configured with an integrated closedloop steam cooling system This system allows higher turbine firing temperature to be achieved
without increasing combustion temperature. This is because exhaust gas temperature drop across
the first stage nozzle is significantly reduced . Another important benefit of the integrated closedloop steam cooling system is the elimination of "chargeable cooling air" for the first and second
stage rotating and stationary airfoils.This technology is expected to provide two percent- age points
thermal efficiency improvement.
The "H" platform gas turbine combined-cycle plants are expected to achieve 60% LHV thermal
efficiency in the first half of this decade. The application of ceramic hot gas path parts and
coatings show promise for further future per- formance gains.
Steam cycle improvements that include increased steam pressure and temperature with
supercritical steam cycles have near-term applications. Current economic analysis indicates,
however, that the thermodynamic gain associated with steam cycles that have steam temperatures
and pressures above the current levels (1050F and 1400 PSIG to 1800 PSIG) cannot be justified in
most cases because of the added costs. As in the past, operating cost (fuel price) and the cost of
new technology development will dictate the trend for increased combined-cycle efficiency.
Pilavachi (2000) gave an overview of power generation with gas turbine and combined heat and
power (CHP) systems and discussed various methods to improve the performance of the several
types of gas turbine cycles.
Heppenstall (1998), described and compared several power generation cycles which have been
developed to take advantage of the gas turbine's thermodynamic characteristics. Emphasis has been
given to systems involving heat recovery from the gas turbine's exhaust and these include the
combined, Kalina, gas/gas recuperation, steam injection, evaporation and chemical recuperation
cycles. Thermodynamic and economic characteristics of the various cycles are considered in order to
10
establish their relative importance to future power generation markets. The present dominance of the
combined cycle as the preferred option for a new plant is thought likely to continue.
Bolland (1991) studied alternative measures to improve the efficiency of combined gas and steam
cycles. A typical modern dual pressure cycle was chosen as reference and alternative arrangements
such as dual pressure with reheat, triple-pressure cycle, triple pressure with reheat, and dual/triple
pressure supercritical reheat cycles were considered. It is observed that with new V94.3 gas turbine,
the combined cycle net efficiency reaches 55% for triple pressure reheat cycle.
The paper Performance Evaluation of a Combined-Cycle Cogeneration System by Huang and
Naumowicz (1999) presents a methodology for performance evaluation of a combined-cycle
cogeneration system. Energy balances and performance assessment parameters of that system are
given. Results for such a system using an advanced gas turbine as the prime mover show that it is a
very versatile system. It 3can produce a large power-to-heat ratio together with high second-law
efficiency over a wide range of process steam pressures.
The paper Performance Simulation of Heat Recovery Steam Generators in a Cogeneration System
by Karthikeyan et al. (1998) gives energy balances for a one pressure level heat recovery steam
generator. Effects of pinch and approach points on steam generation and also on temperature profiles
across heat recovery steam generator are investigated. The effects of operating conditions on steam
production and also on exit gas temperature from the heat recovery steam generator are discussed. It
is concluded that low pinch point results in improved heat recoverysteam generator performance due
to reduced irreversibilities. Additionally, the supplementary firing enhances the steam production.
The book Handbook for Cogeneration and Combined Cycle Power Plants by Boyce (2002) covers
all major aspects of power plant design, operation, and maintenance. It covers cycle optimization and
reliability, technical details on sizing, plant layout, fuel selection, types of drives, and performance
11
12
process pressure on the thermal efficiency and utilization factor is presented. The results show that
the total irreversibility of the cogeneration plant is 38 percent lower compared to the conventional
plant. This reduction in the irreversibility is accompanied by an increase in the thermal efficiency and
utilization factor by 25 and 24 percent, respectively. The results show that the exergy destruction in
the boiler is the highest.
The paper Performance Evaluation of a Combined-Cycle Cogeneration System by Huang and
Naumowicz (1999) presents a methodology for performance evaluation of a combined-cycle
cogeneration system. Energy balances and performance assessment parameters of that system are
given. Results for such a system using an advanced gas turbine as the prime mover show that it is a
very versatile system. It 3can produce a large power-to-heat ratio together with high second-law
efficiency over a wide range of process steam pressures.
The paper Performance Simulation of Heat Recovery Steam Generators in a Cogeneration System
by Karthikeyan et al. (1998) gives energy balances for a one pressure level heat recovery steam
generator. Effects of pinch and approach points on steam generation and also on temperature profiles
across heat recovery steam generator are investigated. The effects of operating conditions on steam
production and also on exit gas temperature from the heat recovery steam generator are discussed. It
is concluded that low pinch point results in improved heat recovery steam generator performance due
to reduced irreversibilities. Additionally, the supplementary firing enhances the steam production.
The book Handbook for Cogeneration and Combined Cycle Power Plants by Boyce (2002) covers
all major aspects of power plant design, operation, and maintenance. It covers cycle optimization and
reliability, technical details on sizing,
A K Tiwari 2012 Published a Paper.This paper is intended to review the literature on research,
development and projects related to gas turbine combined cycle. It focuses on summarizing several
research investigations carried out by the author and associates, during the past years, in the field of
gas turbine combined system. The performance of gas-steam combined cycle power plant depends on
various operating parameters. The power output and efficiency both depends on operation of topping
as well bottoming cycle but mainly depends on topping cycle which is Brayton cycle in this study.
Besides the power output and efficiency there are different losses which occur in different
components of plant. These are based on first and second law of thermodynamics. The second law
approach (exergy analysis) gives better understanding of different losses and optimization of system
13
for higher power output and efficiency. Hence the effect of different parameters on the performance
of combined cycle is reviewed in this paper.
Solvina AB has simulators for different power plants been developed for many years in order for
operators to simulate and train for different possible operating conditions at their power plant. Due to
an increased demand for simulators they have decided to develop two general models of a power
plant, which should be simple to adapt to a given purpose. The two general models comprise one
condensing power plant and one combined cycle power plan
The demand for energy and specifically for electricity has been growing continuously. Today, the
main source of energy for electricity production is based in fossil fuels. The international agency of
energy predicts that in 2030 the largest part of fuel production will be generated from gas fueled
combined cycles power plants (IEA, 2002).
The combined cycle power plant is composed of a gas turbine in combination with a waste heat
boiler which produces steam to a steam turbine consisting of a high pressure part and a low pressure
part, all mounted on the same shaft. This means that the power produced by the steam turbine is
limited by the steam flow, which is dependent on the amount of exhaust gases produced by the gas
turbine.(www.diva-portal.org).
14
CHAPTER 03
15
16
Starting sequence:
The gas turbine cannot run itself from zero speed. A starting means bring the shaft line up to the
self-sustaining speed.
When the starting means is actuated, the IGV are in the closed shut down position and the
compressor bleed valves are open. The cranking torque from the starting means system breaks away
the turbine shaft, the cranking motor brings the gas turbine to firing speed. Fuel is injected in the
combustion chamber, spark plug provide ignition in two combustion chambers and the flame
spreads to the other combustion chambers through the crossfire tubes. Flame detectors confirm full
ignition to the control panel.
Starting means remain actuated to accelerate the unit to self-sustaining speed. A gas turbine speed
threshold stops the starting motor. The gas turbine reaches nominal speed, the IGV move to full
speed no load (FSNL) operating position and the bleed valve closes.
Main shaft driven lube oil pump provides lubricating oil for the shaft line bearings. During
starting sequence the auxiliary lube oil pump feeds the header.
There is no clutch between the starting means and the gas turbine, the torque converter provide
this function between starting means and auxiliary gear box.
Air
Torque output
to drive
accessories and
from starting
Combustion
Axial
flow
Turbine
Compre
ssor
means
17
Description:
The axial-flow compressor section consists of the compressor rotor and the inclosing casing.
Included within the compressor casing are the inlet guide vanes, the 17 stages of rotor and
stator blades, and the exit guide vanes.
In the compressor, air is confined to the space between the rotor and stator blades where it is
compressed in stages by a series of alternate rotating (rotor) and stationary (stator) airfoilshaped blades.
The rotor blades supply the force needed to compress the air in each stage and the stator blades
guide the air so that it enters in the following rotor stage at the proper angle. The compressed
air exits through the compressor discharge casing to the combustion chambers. Air is extracted
from the compressor for turbine cooling, for bearing sealing, and during start- up for pulsation
control.
Since minimum clearance between rotor and stator provides best performance in a compressor,
parts have to be made and assembled very accurately.
COMPRESSOR SECTION
18
The forward stub-shaft is machined to provide the forward and aft thrust faces and the
journal for the n 1 bearing, as well as the sealing surfaces for the n 1 bearing oil seals and the
compressor low pressure air seals.
19
These sections, in conjunction with the turbine shell and exhaust frame form the primary
structure of the gas turbine. They support the rotor at the bearing points and constitute the outer
wall of the gas path annulus.
The casing bore is maintained to close tolerances with respect to the rotor blade tips for
maximum efficiency.
20
Blading:
The compressor rotor and stator blades are airfoil shaped and designed to compress air
efficiently at high blade tip velocities. The blades are attached to their wheels by dovetails
arrangements.
The dovetail is very precise in size and position so as to maintain each blade in the desired
position and location on the wheel.
The compressor stator blades are airfoil shaped and are mounted by similar dovetails into
ring segments. The ring segments are inserted into circumferential grooves in the casing and are
held in place with locking keys. The stator blades of the last nine stages and two exit guide
vanes have a square base dovetail that are inserted directly into circumferential grooves in
the casing. Locking keys also hold them in place.
21
22
Combustion wrapper:
The combustion wrapper forms a plenum in which the compressor discharge air flow is
directed to the combustion chambers. Its secondary purpose is to act as a support for the
combustion chamber assemblies. In turn, the wrapper is supported by the compressor
discharge casing and the turbine shell.
Combustion chambers:
Discharge air from the axial flow compressor flows into each combustion flow sleeve from the
combustion wrapper (see figure). The air flows up-stream along the outside of the
combustion liner toward the liner cap. This air enters the combustion chamber reaction zone
through the fuel nozzle swirl tip, through metering holes in both the cap and liner and through
combustion holes in the forward half of the liner.
The hot combustion gases from the reaction zone pass through a thermal soaking zone and then
23
into a dilution zone where additional air is mixed with the combustion gases. Metering holes in
the dilution zone allow the correct amount of air to enter and cool the gases to the desired
temperature. Along the length of the combustion liner and in the liner cap are openings whose
function is to provide a film of air for cooling the walls of the liner and cap as shown in figure.
Transition pieces direct the hot gases from the liners to the turbine nozzles. All fourteen
combustion liners, flow sleeves and transition pieces are identical.
Crossfire tubes:
All fourteen combustion chambers are interconnected by means of crossfire tubes. These tubes
enable flame from the fired chambers to propagate to the unfired chambers.
These spring-injected and pressure-retractable plugs receive their energy from ignition
transformers. At the time of firing, a spark at one or both of these plugs ignites the gases in a
chamber; the remaining chambers are ignited by crossfire through the tubes that
interconnect the reaction zones of the remaining chambers. As rotor speed increases,
chamber pressure causes the spark plugs to retract and the electrodes are removed from the
combustion zone.
Flame detectors:
During the starting sequence, it is essential that an indication of the presence or absence of
flame be transmitted to the control system. For this reason, a flame monitoring system is
used consisting of four sensors which are installed on four combustion chambers (n 4 and
5, 10 and 11) and an electronic amplifier which is mounted in the turbine control panel.
The ultraviolet flame sensor consists of a flame sensor containing a gas filled detector. The gas
within this flame sensor detector is sensitive to the presence of ultraviolet radiation which is
emitted by a hydrocarbon flame. A D.C. voltage, supplied by the amplifier, is impressed across
the detector terminals. If flame is present, the ionization of the gas in the detector allows
conduction in the circuit which activates the electronics to give an output defining flame.
Conversely, the absence of flame will generate an opposite output defining "no flame".
After the establishment of flame, if voltage is re-established to the sensors defining the
loss (or lack) of flame a signal is sent to a relay panel in the turbine electronic control circuitry
25
where auxiliary relays in the turbine firing trip circuit, starting means circuit, etc... shut down
the turbine. The FAILURE TO FIRE or LOSS OF FLAME is also indicated on the
annunciator. If a loss of flame is sensed by only one flame detector sensor, the control circuitry
will cause an annunciation only of this condition.
For more information about the flame detectors, see Gas turbine equipment publications
volumes for G.T. control and protection system)
Atomizing air is utilized with liquid fuel to assist in the formation of a finely divided spray.
The liquid fuel and atomizing air enter the fuel nozzle assembly through separate
connections. Then, they are introduced through separate but concentric passages in the nozzle
body. Fuel enters the inner passage.
26
Gas fuel enters the fuel nozzle assembly through the fuel gas connection flange and is
routed through nozzle internal passages to orifices located in the gas tip.
TRANSITION PIECE
27
The false start drain valves, normally open, close during start-up when the turbine speed
reaches a sufficient value. Air pressure from the axial flow compressor discharge is used to
actuate these valves.
During the turbine shut-down sequence, the valves open as compressor speed drops
(compressor discharge pressure is reduced).
28
3.1.11
TURBINE SECTION
Description:
The three stage turbine section is the area in which energy in the form of high energy pressured
gas, produced by the compressor and combustion sections, is converted to mechanical
energy.
Each turbine stage is comprised of a nozzle and the corresponding wheel with its buckets.
Turbine section components include the turbine rotor, turbine shell, nozzles, shrouds,
exhaust frame and exhaust diffuser.
TURBINE SECTION
29
TURBINE ROTOR
Structure:
The turbine rotor assembly consists of two wheel shafts; the first, second, and third-stage
turbine wheels with buckets; and two turbine spacers. Concentricity control is achieved with
mating rabbets on the turbine wheels, wheel shafts, and spacers. The wheels are held together
with through bolts. Selective positioning of rotor members is performed to minimize balance
corrections.
The forward wheel shaft extends from the first-stage turbine wheel to the aft flange of the
compressor rotor assembly. The journal for the n 2 bearing is a part of the wheel shaft.
The aft wheel shaft connects from the third-stage turbine wheel to the load coupling. It includes
the n 3 bearing journal.
Spacers between the first and second, and between the second and third-stage turbine wheels
determine the axial position of the individual wheels. These spacers carry the diaphragm
sealing bands. The spacer forward face includes radial slots for cooling air passages. The 1-2
spacer also has radial slots for cooling air passages on the aft face.
Buckets:
The turbine buckets (figure next page) increase in size from the first to the third-stage. Because
of the pressure reduction resulting from energy conversion in each stage, an increased annulus
area is required to accommodate the gas flow ; thus necessitating increasing the size of
the buckets. The first-stage buckets are the first rotating surfaces encountered by the
extremely hot gases leaving the first-stage nozzle. Each first-stage bucket contains a series
of longitudinal air passages for bucket cooling. Air is introduced into each first-stage bucket
through a plenum at the base of the bucket dovetail. It flows through cooling holes extending
the length of the bucket and exits at the recessed bucket tip. The holes are spaced and sized to
obtain optimum cooling of the airfoil with minimum compressor extraction air.
30
Like the first-stage buckets, the second-stage buckets are cooled by spanwise air passages the
length of the airfoil. Since the lower temperatures surrounding the bucket shanks do not require
shank cooling, the second-stage cooling holes are fed by a plenum cast into the bucket shank.
Spanwise holes provide cooling air to the airfoil at a higher pressure than a design with shank
holes. This increases the cooling effectiveness in the airfoil so airfoil cooling is
accomplished with minimum penalty to the thermodynamic cycle.
The third-stage buckets are not internally air cooled; the tips of these buckets, like the
second-stage buckets, are enclosed by a shroud which is a part of the tip seal. The shrouds
interlock from bucket to bucket to provide vibration damping.
Turbine buckets for each stage are attached to their wheels by straight, axial entry, multiple tang
dovetails that fit into matching cutouts in the turbine wheel rims. Bucket vanes are connected to
their dovetails by means of shanks. These shanks locate the bucket-to-wheel attachment at a
significant distance from the hot gases, reducing the temperature at the dovetail. The turbine
rotor assembly is arranged so that the buckets can be replaced without unstacking the wheels,
spacers, and wheel shaft assemblies.
31
BUCKETS
The turbine rotor must be cooled to maintain reasonable operating temperatures and,
therefore, assure a longer turbine service life.
Cooling is accomplished by means of a positive flow of cool air radially outward through a
space between the turbine wheel with buckets and the stator, into the main gas stream. This area
is called the wheel space.
32
The turbine rotor is cooled by means of a positive flow of relatively cool (relative to hot gas
path air) air extracted from the compressor. Air extracted through the rotor, ahead of the
compressor 17th stage, is used for cooling the 1st and 2nd stage buckets and the 2nd stage aft
and 3rd stage forward rotor wheel spaces. This air also maintains the turbine wheels, turbine
spacers, and wheel shaft at approximately compressor discharge temperature to assure low
steady state thermal gradients thus ensuring long wheel life.
The first stage forward wheelspace is cooled by air that passes through the high pressure
packing seal at the aft end compressor rotor. The 1st stage aft and 2nd stage forward wheel
spaces are cooled by compressor discharge air that passes through the stage 1 shrouds and then
radially inward through the stage 2 nozzle vanes. The 3rd aft wheelspace is cooled by cooling
air that exits from the exhaust frame cooling circuit.
33
TURBINE STATOR
Structure:
The turbine shell and the exhaust frame constitute the major portion of the gas turbine stator
structure. The turbine nozzles, shrouds, n 3 bearing and turbine exhaust diffuser are
internally supported from these components.
Turbine shell:
The turbine shell controls the axial and radial positions of the shrouds and nozzles. It determines
turbine clearances and the relative positions of the nozzles to the turbine buckets. This
positioning is critical to gas turbine performance.
Hot gases contained by the turbine shell are a source of heat flow into the shell. To control the
shell diameter, it is important that the shell design reduces the heat flow into the shell and limits
its temperature. Heat flow limitations incorporate insulation, cooling, and multilayered
structures. The external surface of the shell incorporates cooling air passages. Flow through
these passages is generated by an off base cooling fan.
Structurally, the shell forward flange is bolted to flanges at the aft end of the compressor
discharge casing and combustion wrapper. The shell aft flange is bolted to the forward flange of
the exhaust frame. Trunnions cast onto the sides of the shell are used with similar
34
trunnions on the forward compressor casing to lift the gas turbine when it is separated from its
base.
Turbine nozzles:
In the turbine section, there are three stages of stationary nozzles which direct the high velocity
flow of the expanded hot combustion gas against the turbine buckets, causing the rotor to
rotate. Because of the high pressure drop across these nozzles, there are seals at both the inside
diameters and the outside diameters to prevent loss of system energy by leakage. Since these
nozzles operate in the hot combustion gas flow, they are subjected to thermal stresses in
addition to gas pressure loadings.
The first stage nozzle receives the hot combustion gases from the combustion system via the
transition pieces. The transition pieces are sealed to both the outer and inner sidewalls on the
entrance side of the nozzle, so minimizing leakage of compressor discharge air into the nozzles.
The 18 cast nozzle segments, each with two partitions (or airfoils) are contained by a
horizontally split retaining ring which is center-line supported to the turbine shell on lugs at the
sides and guided by pins at the top and bottom vertical center-lines. This permits radial growth
of the retaining ring, resulting from changes in temperature while the ring remains centered in
the shell.
The aft outer diameter of the retaining ring is loaded against the forward face of the
first stage turbine shroud and acts as the air seal to prevent leakage of compressor discharge air
between the nozzle and shell. On the inner sidewall, the nozzle is sealed by direct bearing of the
nozzle inner load rail against the first-stage nozzle support ring bolted to the compressor
discharge casing. The nozzle is prevented from moving forward by four lugs welded to the aft
outside diameter of the retaining ring at 45 degrees from vertical and horizontal centerlines.
These lugs fit in a groove machined in the turbine shell just forward of the first stage shroud Thook. By moving the horizontal joint support block and the bottom centerline guide pine, the
lower half of the nozzle can be rolled out with the turbine rotor in place.
35
The third stage nozzle receives the hot gas as it leaves the second stage buckets, increases its
velocity by pressure drop and directs this flow against the third stage buckets.
The nozzle consists of 16 cast segments, each with four partitions (or airfoils). It is held at
the outer sidewall forward and aft sides in grooves in the turbine shrouds in a manner
identical to that used on the second stage nozzle. The third stage nozzle is circumferentially
positioned by radial pins from the shell.
Diaphragms:
Attached to the inside diameters of both the second and third stage nozzle segments are the
nozzle diaphragms (figure here after).
These diaphragms prevent air leakage past the inner sidewall of the nozzles and the turbine
36
rotor. The high/low, labyrinth-type seal teeth are machined into the inside diameter of the
diaphragm. They mate with opposing sealing lands on the turbine rotor. Minimal radial
clearance between stationary parts (diaphragm and nozzles) and the moving rotor are
essential for maintaining low inter stage leakage; this results in higher turbine efficiency.
Shrouds:
Unlike the compressor blading, the turbine bucket tips do not run directly against an integral
machined surface of the casing but against annular curved segments called turbine shrouds.
The primary function of the shrouds is to provide a cylindrical surface for minimizing tip
clearance leakage.
The secondary function is to provide a high thermal resistance between the hot gases and the
comparatively cool shell. By accomplishing this function, the shell cooling load is drastically
reduced, the shell diameter is controlled, the shell roundness is maintained, and important
turbine clearances are assured.
The shroud segments are maintained in the circumferential position by radial pins from
the shell. Joints between shroud segments are sealed by interconnecting tongues and grooves.
radial struts. On the inner gas path surfaces of the two cylinders are attached the inner and outer
diffusers. The no.3 bearing is supported from the inner cylinder.
The exhaust diffuser, located at the extreme aft end of the gas turbine, bolts to, and is
supported by, the exhaust frame. The exhaust frame is a fabricated assembly consisting of an
inner cylinder and an outer divergent cylinder that flairs at the exit end at a right angle to the
turbine centerline. At the exit end of the diffuser between the two cylinders are five
turning vanes mounted at the bend. Gases exhausted from the third turbine stage enter the
diffuser where velocity is reduced by diffusion and pressure is recovered. At the exit of the
diffuser, turning vanes direct the gases into the exhaust plenum.
Exhaust frame radial struts cross the exhaust gas stream. These struts position the inner
cylinder and no.3 bearing in relation to the outer casing of the gas turbine. The struts must be
maintained at a uniform temperature in order to control the center position of the rotor in
relation to the stator. This temperature stabilization is accomplished by protecting the struts
from exhaust gases with a metal fairing fabricated into the diffuser and then forcing cooling
air into this space around the struts.
Turbine shell cooling air enters the space between the exhaust frame and the diffuser
and flows in two directions. The air flows in one direction into the turbine shell cooling
annulus and also down through the space between the struts and the airfoil fairings surrounding
the struts and subsequently into the load shaft tunnel and turbine third-stage aft wheel space.
38
EXHAUST DUSER
3.1.13
BEARINGS
Introduction:
The MS 9001 E gas turbine unit contains three main journal bearings used to support the
gas turbine rotor. The unit also includes thrust bearings to maintain the rotor-to-stator axial
position. These bearing assemblies are located in three housings: one at the inlet, one in the
compressor discharge casing, and one in the exhaust frame. All bearings are pressurelubricated by oil supplied from the main lubricating oil system. The oil flows through branch
lines to an inlet in each bearing housing.
39
BEARINGS
BEARING NO.
1
2
3
1
1
CLAS
Journal
S
Journal
Journal
Loaded
Unloaded thrust
thrust
TYP
Elliptic
E
Elliptic
al
Elliptic
al
Self-aligned (equalized)
al
Tilting
pad
Lubrication:
The three main turbine bearings are pressure-lubricated with oil supplied by the 12540 liters
capacity lubricating oil reservoir. Oil feed piping, where practical, is run within the lube oil
reservoir drain line, or drain channels, as a protective measure. This procedure is referred to as
double piping and its rationale is that in the event of a pipe-line leak, oil will not be lost or
sprayed on nearby equipment, thus eliminating a potential safety hazard.
When the oil enters the bearing housing inlet, it flows into an annulus around the bearing
liner. From the annulus the oil flows through machined slots in the liner to the bearing
surface. The oil is prevented from escaping along the turbine shaft by labyrinth seals.
Oil seals:
Oil on the surface of the turbine shaft is prevented from being spun along the shaft
by oil seals in each of the three bearing housings. These labyrinth packings and oil
deflectors (teeth type) are assembled on both sides of the bearing assemblies where oil control
is required. A smooth surface is machined on the shaft and the seals are assembled so that
only a small clearance exists between the oil and seal deflector and the shaft. The oil seals are
designed with two rows of packing and an annular space between them. Pressurized sealing air
is admitted into this space and prevents lubricating oil from spreading along the shaft. Some of
this air returns with the oil to the main lubricating oil reservoir and is vented through a lube oil
vent.
40
ENCLOSURES
The gas turbine and the relevant auxiliaries are installed on site within enclosures. The aim of
those enclosures is:
To provide weather protection for the equipment.
To detect and extinguish the fire and to contain fire fighting medium.
To provide proper cooling and ventilation for the equipment.
To dilute gas leak to avoid hazardous area.
To provide attenuation of the noise generated by the equipment.
To protect personnel from high temperature and fire risks.
To heat the enclosure during cold period.
inlet, caused by the rotating compressor blades. More details are given in the "Technical
equipment tab, especially about the filtering installation.
EXHAUST SYSTEM
In the exhaust section, the gases, which have been used to power the turbine wheels, are
redirected to be either released to atmosphere or towards a heat recovery boiler when it is the
case.
After leaving the exhaust frame, the hot gases reach the diffuser, located in the exhaust plenum.
On the exhaust plenum wall facing the exhaust diffuser, a circular arrangement of thermocouples
permits exhaust gas temperature measurement. The thermocouples send their signals to the gas
turbine temperature control and protection system.
42
43
3.2 HRSG
As stated in Combine Cycle Theory, the combined cycle setup is a combination of a simple cycle
gas turbine (Brayton cycle) and a steam power cycle (Rankine cycle). The Brayton cycle consists
of the compressor, combustor, and combustion turbine.
The first island within the combined-cycle power block is the combustion turbine (CT)
generator set.
The HRSG absorbs heat energy from the exhaust gas stream of the combustion turbine. The
absorbed heat energy is converted to thermal energy as high temperature and pressure steam. The
high-pressure steam is then used in a steam turbine generator set to produce rotational
mechanical energy. The shaft of the steam turbine in connected to an electrical generator that
then produces electrical power.
The waste heat is recovered from the combustion turbine exhaust gas stream through absorption
by the HRSG. The exhaust gas stream is a large mass flow with temperature of up to 1,150F.
44
Most large HRSGs can be classified as a double-wide, triple-pressure level with reheat,
supplementary fired unit of natural circulation design, installed behind a natural gas fired
combustion turbine.
The steam generated by the HRSG is supplied to the steam turbine that drives the electrical
generator system.
Reheat (RH)
45
All generated steam from the HP, RH, and LP systems is supplied to the steam turbine, except
for some LP steam used for deaeration, The IP steam is mixed with the cold RH return loop prior
to being admitted to the steam turbine.
Typical heat recovery steam generator circuits have four major components
Superheaters
Evaporators
Economizers
Drum
46
HRSG Boiling
Boiling occurs in the evaporator of a typical steam generator circuit. This process changes the
phase of water from liquid to vapor or steam. The steam is generated at the saturation
temperature associated with the operating pressure.
When water is heated in an evaporator section and steam is generated, an increase in evaporator
section pressure occurs. As the pressure increases, the temperature of the boiler water rises.
Recall, the temperature at which boiling occurs for any given pressure is constant and is called
the saturation temperature. Therefore, the temperature of the water and the steam are equal since
both are "saturated" with energy just in a different phase.
Two distinct types of boiler regimes have been observed. These regimes are referred to
as nucleate and film boiling.
47
Nucleate boiling is characterized by the formation and release of steam bubbles from the
solid/liquid wetted tube wall interface.
Film boiling occurs when a steam film covers the tube wall.
48
Flow Paths
50
Steam Drum
The HRSG is equipped with a high-, intermediate-, and low-pressure steam drums. The steam
drums are steam/water separators, storage tanks, and water treatment sites for steam purity
control.
Drum boilers operate in the area on the saturation curve. The steam/water mixture entering the
drum from the riser tubes usually is 5-10% steam depending on the boiler load and pressure.
Staying at low-quality levels protects the tubes from overheat failures due to the nature of the
boiling process.
In the steam drum, saturated steam is separated from the steam/water mixture. The separated
steam rises up through the drum as feedwater enters the drum from the economizer. The
separated water from the steam/water mixture is then recirculates together with the feedwater to
the heat absorbing evaporator tubes through the circulation loop. The steam/water separation is
done through a combination of gravity and mechanical components.
Downcomers/Feeder Headers
The downcomer/feeder headers are important components within the natural circulation
evaporator module loop. The downcomer conveys water from the steam drum to the feeder
header. The feeder header receives the water from the downcomer and distributes water to the
evaporator modules.
Downcomer inlets are equipped with vortex breakers that disrupt the swirling motion of the
water flowing from the drum and into the downcomer. The downcomer inlets are also covered
with a mesh screen to prevent accidental dropping of tools and other materials during inspection
and maintenance. The feeder header also acts as a sediment trap that must be blown clear from
the evaporator circuit. The feeder header also contains connections for chemical cleaning, drain
lines, and intermittent blowoff.
51
Evaporator
Evaporator sections are where the boiling process or steam generation occurs. As heat energy is
absorbed by water from the gas stream, the water temperature increases. When water reaches the
boiling point or saturation temperature, some of the water evaporates or vaporizes to steam. The
evaporator sections are single-pass, two- and three-row modules. The single pass is on the water
side and is vertically up. The modules feed a steam/water mixture to the riser pipes. The modules
are fed with water from the downcomer/feeder header assembly to replace the water exiting as a
steam/water mixture.
Superheater
The last major component of a steam generator circuit is the superheater. The major function of a
superheater is to increase steam temperature above saturation. High steam temperature
minimizes the introduction of water as liquid to the steam turbine and improves steam cycle
efficiency. The superheater absorbs heat energy from the CT exhaust gas and transfers this
energy to the steam. The steam superheat energy level is measured as an increase in steam
temperature beyond the steam temperature achieved in the evaporator section. The superheater
sections typically have the highest metal temperatures in the HRSG. Superheater sections are
composed of extended or finned tube surface modules. The high-pressure superheater modules
are one-pass, two-row modules and are arranged in a series/parallel configuration to reach the
desired final steam temperature and capacity.
52
Setting System
The setting system provides CT exhaust gas containment ductwork, encasement of the various
heat recovery module units, access to equipment via platforms, ladder and stair systems, duct
expansion joints, casing penetration seals, and the exhaust stack. The HRSG setting includes
ductwork transitions for connections with the CT exhaust and the HRSG module boxes.
Pressure Parts
HRSG Casing
The HRSG casing is typically carbon steel, specification A-36 or SA-283, and is reinforced with
A-36 carbon steel structural steel on the exterior to withstand the specified internal design
pressure wind load and seismic load. Construction is all welded gas-tight to prevent external gas
leakage, including both shop and field joints. The HRSG module box assemblies are internally
lined partially with multiple layers of ceramic fiber insulation covered with liner panels to reduce
heat transfer of CT gases to exterior surfaces. Stainless steel liner panels are usually attached to
the ductwork with stainless steel studs welded to the inside surfaces of the carbon steel casing.
The liner panels are designed to provide for differential expansion between the hot interior of the
pressure containment ducts and casing of the modular units.
Outlet Stack
The stack is typically an all-welded, free-standing, self-supported, uninsulated, A-36 carbon steel
structure. The stack is connected to the outlet of the HRSG with uninsulated ductwork or
breaching and an expansion joint. The stack is usually equipped with EPA test ports. All of these
items are accessible by the ladder and platform system supplied.
Expansion Joints
The HRSG is equipped with one fabric expansion joint between the outlet of the HRSG and the
stack breaching. The fabric belt is clamped to the frame by a series of bolts and bars that provide
the sealing pressure to the edge of fabric around the entire periphery of the belt.
53
Casing Penetrations
Piping that penetrates the casing is sealed by a bellows-type metallic expansion joint. Each
bellows has been specifically designed and selected for the predicted thermal differential
movements between the pipe and the casing.
High-Pressure Economizer
Each module is multipass on the water side and single-pass on the gas side. This is accomplished
by internal baffles in the upper and lower module headers.
The HPEC receives feedwater from the feed pumps (provided by others) and absorbs heat from
the CT exhaust gas, lowering the CT exhaust gas temperature and raising the water temperature
to near saturation prior to entering the high-pressure steam drum.
High-Pressure Evaporator
In the HP EVAP section, the phase change between water and steam occurs. This phase change
occurs due to the convective heat transfer or energy exchange between the CT exhaust gas
stream and the water in the HP EVAP modules. The HP EVAP modules are all single-pass with
no upper and lower header internal baffles. Steam/water mixture flows in upward direction
through the tubes and escapes to the steam drum via riser system. Water is fed to the modules
from the two downcomer feeder header assemblies. This is referred to as a natural circulation
loop.
54
High-Pressure Superheater
Steam on the inside of the tubes is received from the high-pressure steam drum at saturated
temperature and is heated to final steam temperature.
Low-Pressure Evaporator
The LP EVAP modules are all single-pass with no upper and lower header internal baffles. The
modules are oriented in this direction to allow steam bubbles generated to escape via the riser
tubes to the steam drum. Water is fed to the modules from the downcomer feeder header
assemblies. This is referred to as a natural circulation loop.
56
Low-Pressure Superheater
Steam on the inside of the tubes is received from the steam drum at saturated temperature and is
heated to final steam temperature.
Feedwater Preheater
The modules have multiple passes on the water side. This is accomplished by internal baffles in
the upper and lower headers.
The FW PHTR receives feedwater from the condensate pump system and absorbs heat from the
gas turbine exhaust, lowering the gas temperature and raising the water temperature. The FW
PHTR increases HRSG efficiency.
57
58
Steam Turbine:
A steam turbine is a prime mover in which rotary motion is obtained by the gradual change
of momentum of the steam.
The blades are set round the circumference of the turbine disc. The tips of the blades are
connected together, for rigidity, by means of the blade shroud ring. The turbine disc is free to
rotate on a shaft. Set to the side of the blades, and at an angle to them, are steam nozzles. By
means of nozzles, the high-pressure steam is made to give up some of its energy to produce a
large increase in kinetic energy of the steam. The steam thus leaving the nozzles at high velocity
passes over the blades and the turbine disc rotates. Then power can be taken from the shaft. The
turbine discs and the nozzles are fitted into a casing.
Following are the important advantages of steam turbine over reciprocating steam engine
1. A steam turbine may develop higher speeds and a greater steam range is possible.
2. The efficiency of steam turbine is higher.
3. The steam consumption is higher.
59
4. Since all the moving parts are enclosed in a casing, the steam turbine is comparatively
safe.
5. A steam turbine required less space and lighter foundations, as there are little vibrations.
6. There is less frictional loss due to fewer sliding parts.
7. The applied torque is more uniform to the driven shaft.
8. A steam turbine requires less attention during running. Moreover the repair are generally
less.
Impulse Turbine
(ii)
Reaction Turbine.
(ii)
Condensing Turbine
(ii)
Non-condensing Turbine
(ii)
(iii)
(ii)
Multi-stage Turbine.
60
Impulse Turbine
In impulse turbine, steam expands in nozzle until the pressure reaches the pressure of the
region in which the turbine wheel rotates. The steam jet issuing from the nozzle at a high
velocity is then collided against the blades of the turbine wheel, and the impulse of the jet
produces rotation of the turbine wheel. If whole pressure drop from boiler to condenser pressure
takes place in a single nozzle row, then the steam velocity entering the turbine is very high. If
some of this velocity is used up in single row of turbine blading, then the speed of rotation is
very high.
1.
Velocity Compounding
In this type steam is expanded in a single row of nozzles. The high velocity steam leaving
the nozzle passes on the first row of moving blades where its velocity is only partially reduced.
The steam leaving the first row of moving blades passes into a row of fixed blades that are
mounted in the turbine casing.
This row of fixed blades serves to redirect the steam back to the direction of motion such that it
is correct for entry into a second row of moving blades that are mounted on the same turbine disc
as the first row of moving blades. The steam velocity is again partially reduced in the second row
of moving blades.
62
2.
PRESSURE COMPOUNDING
In this type steam enters a row of nozzles where its pressure is only partially reduced and
its velocity is increased. The high velocity steam passes from the nozzles on to the row of
moving blades where its velocity is reduced. The steam then passes into a second row of nozzles
where its pressure is again partially reduced and its velocity is again increased. The high velocity
steam passes from the nozzles on to a second row of moving blades where its velocity is again
reduced. The steam then passes into a third row of nozzles and so on.
REACTION TURBINE
In the reaction type of turbine, steam flows through stationary blades, and then through
passages between blades at the circumference of the rotor. These passages are filled with steam
63
throughout the entire circumference, the steam is partially expanded in the stator passages, and
the rotor blades are so made that part of the expansion occur in the rotor, in pure (theoretical)
reaction turbine the passages in the stator would not be nozzle shaped, and the expansion would
take place wholly in the nozzle-shaped passages between the blades at the periphery of the rotor.
In the actual turbine, expansion takes place in both stationary and moving nozzle passages, and
the pressure at entrance to each rotating blade is therefore greater than at the exit.
1. Casing:
It is an air-tight metallic case, in which the steam from the boiler, under a high
pressure and temperature, is distributed around the fixed blades (guide mechanism) in the
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casing. The casing is designed in such a way that the steam enters the fixed blades with a
uniform velocity.
2. Guide Mechanism:
It is a mechanism, made up with the help of guide blades, in the form
of a wheel. This wheel is, generally, fixed to the casing; that is why these guide blades are
also called fixed blades. The guide blades are properly designed in order to:
(a) allow the steam to enter the runner without shock. This is done by keeping the relative
velocity at inlet of the runner tangential to the blade angle.
(b) Allow the required quantity of steam to enter the turbine. This is done by adjusting the
openings of the blades.
The guide blades may be opened or closed by rotating the regulating shaft, thus allowing
the steam to flow according to the need. The regulating shaft is operated by means of a
governor whose function is to govern the turbine (i.e. to keep to speed constant at varying
loads)
3. Turbine Runner:
The turbine runner of reaction turbine essentially consists of runner
blades fixed to a shaft or rings, depending upon the type of turbine. The blades, fixed to the
runner, are properly designed in order to allow the steam to enter and leave the runner
without shock.
The surface of the turbine runner is mad very smooth to minimize the frictional
losses. The turbine runner is, generally, cast in one piece. But sometimes, it is made up of
separate steel plates welded together.
4. Draft Tube:
The steam, after passing through the runner, flows into the condenser through
a tube called draft tube. It may be noted that if this tube is not provided in the turbine, then
the steam will move freely and will cause steam eddies.
65
In order to meet the requirements for start-up of the turbine, when the first
When the turbine trips, the bypass pressure-adjusting valve will quickly
66
During the turbine standup and operation with load less that 40% of the rated load, live
steam source provides area from cracks and damage caused by thermal stress, the gland steam is
resuperheated prior to entering glands. During the operation, the low pressure gland steam
temperature shall be within the range of 121-150oC. The temperature difference between
temperature of HP gland steam and that of HP gland cylinder and wall shall not exceeds 100 oC.
For the HP gland, HP gland water spraying stop valve is furnished to avoid water spraying with
supplied temp, lower that 150oC.
During the turbine start-up and operation at low load, the pressure inside the cylinder is
lower than that of atmosphere. Therefore, gland at one side enters into cylinder through the
sealing gland and the other side; the steam enters to the outer chamber. The air drops into outer
chamber of sealing gland from outside and is mixed with the gland steam there. The fan mounted
on the gland condenser maintains a little bit lower pressure than the atmosphere one. In the gland
condenser, the mixed air and gland steam is cooled and condensate is heated.
When the turbine is operated at load higher than 40% of the rated one than the steam pressure
after the first stage increases progressively. When this pressure exceeds in inner chamber, it
forces the gland steam there to flow reversely through the turbine inner gland ring. A self-sealing
system is formed. At this moment, the main stop-adjusting valve should be fully closed. The
gland steam exhaust pressure-adjusting valve will adjust the pressure in gland main to maintain
within the range of 1.07 to 1.1 bar. The set point of its pressure regulator 1.10 bar.
67
1. Nozzle Loss: It is an important loss in impulse turbine, which occurs when the steam
flows through the nozzle. This loss take place due the friction in the nozzle and formation
of eddies losses.
2. Blade Friction Loss: It is an important loss in both the impulse and reaction turbine which
occurs when steam glides over the blades. This loss take place due to the friction of the
surface of the blade. As a result of the blade friction, the relative velocity of the steam is
reduced while gliding over the blades.
3. Wheel Friction Loss: It is another important loss in both impulse and reaction turbines
which occurs when the turbine wheel rotates in the steam. This loss take place due to
resistance offered by the steam to the moving turbine wheel. As a result of this loss the
turbine wheel rotates at a lower speed.
4. Mechanical Friction Loss: It is a loss in both the turbines which occurs due to friction
between and wheel bearing as well as regulating valve. This loss can be reduced by
lubricating the moving parts of the turbines.
5. Leakage Loss: It is a loss in both the turbines, which occurs due to the leakage of steam
at each stage of a turbine, blade tips and glands.
6. Residual Velocity Loss: It is a loss in both the turbines which occurs due to kinetic
energy of the steam, as it leaves the turbine wheel. This loss is reduced by using
multistage wheels.
7. Moisture Loss: It is loss in both the turbines, which takes place due moisture present in
the steam. This loss occurs when the steam passing through the lowest stages becomes
wet. The velocity of water particles is less than that of steam. As a result of this, the
steam has to drag the water particles, which reduces the kinetic energy of the steam.
8. Radiation Losses: It is a loss in both the turbines, which take place due to the difference
of temperature between the turbine casing and the surrounding atmosphere. This is
reduced by properly insulating the turbine.
9. Governing Loss: It is the loss in both the turbines, which occurs due to throttling of the
steam at the main stop valve of the govern
68
69
70
Surface Condensers
Surface condensers are most common types used in power plants.
They are essentially shell-and-tube type heat exchanger, in which the primary heat
transfer mechanism is the condensing of the saturated steam on the outside of the tubes
and the forced convection heating of the circulating water inside the tubes. In surface
condensers there is no direct contact between the steam and cooling water and the impure
water can be used for cooling purpose. Although the capital cost and the space needed is
more in surface condenses but it is justified by the saving in running cost and increases in
efficiency of plant achieved by using this condenser.
71
1.
the tubes in one direction lower half comes out in the opposite direction in the upper half.
2.
pumped away from the centre of the condenser. The condensate moves radially towards
the centre of the centre of tube nest. Some of the exhaust steam while moving towards the
centre meets the under cooled condensate and pre-heats it thus reduces under cooling.
Cooling tower
72
73
A. HeatingValues
The heat of combustion, heating value or calorific value of a fuel is the amount of
energy generated by the complete combustion of a unit mass of fuel. The US system
of measurement uses British thermal units (Btu) per pound or Btu per standard cubic
foot when expressed on a volume basis. The heating value of a gas fuel may be
determined experimentally using a calorimeter in which fuel is burned in the presence of
air at constant pressure. The products are allowed to cool to the initial temperature and a
measurement is made of the energy released during complete combustion. All fuels that
contain hydrogen release water vapor as a product of combustion, which is
subsequently condensed in the calorimeter. The resulting measurement of the heat
released is the higher heating value (HHV), also known as the gross heating value, and
includes the heat of vaporization of water. The lower heating value (LHV), also known
as the net heating value, is calculated by subtracting the heat of vaporization of water
from the measured HHV and assumes that all products of combustion including water
remain in the gaseous phase.
74
C. Superheat Requirement
The superheat requirement is establish to ensure that the fuel gas supply to the
gas turbine is 100% free of liquids. Superheat is the temperature difference between
the gas temperature and the respective dew point. The requirement is independent of
the hydrocarbon and moisture concentration.
gas
fuel
moisture dew
point
is
dependent
(pounds per million standard cubic feet), the resulting dew point is practically
independent of the gas fuel composition (other than moisture).
75
F. Flammability Ratio
Fuel gases containing
hydrogen
will have a
ratio of rich-to- lean flammability limits that is significantly greater than that of natural
gas. Typically, gases with greater than 5% hydrogen by volume fall into this range and
require a separate startup fuel. GE will evaluate the gas analysis to determine the
requirement for a start-up fuel. Fuel gases with large percentages of an inert gas such as
nitrogen or carbon dioxide will have a ratio of rich-to- lean flammability limits less
than that of natural gas. Flammability ratios of less than 2.2 to 1 based on volume
at ISO conditions (14.696 psia and 59F), may experience problems maintaining stable
combustion over the full operating range of the turbine.
G.GasConstituent
Limits
Gas constituent limits are specified to assure stable combustion through all gas
turbine loads and modes of operation. A detailed gas analysis must be furnished to GE
for proper evaluation.
3.5.4 Evaluation
Before the unloading of HSFO in untreated tanks, following procedure is
taken for evaluation.
To evaluate a liquid fuel for gas turbine application certain physical and chemical data
are required.
A. Sampling
Since analyses of small traces of metals are involved, and since some tests use small
amounts of sample, it is very important that the fuel sample is uniform and
representative of the fuel as received by the user or shipped by the supplier. If the fuel
is taken from a container, it should be thoroughly mixed mechanically before sampling.
For sampling from storage tanks, refer to ASTM Standard Methods for Sampling
Petroleum Products, D 4057 and D 4177.
The sample for analysis should be stored preferably in plastic or plastic-lined metal
containers. Avoid metal cans with soldered seams and containers with seals (rubber)
that can disintegrate and contaminate the fuel. The container should only be about twothirds full so that it may be well shaken before taking analytical samples. Heavy residual
fuels should be in wide-mouth containers.
C. Viscosity
Viscosities at two temperatures are needed for a viscosity-temperature relationship for
the fuel; the two temperatures normally being 100F (37.8C) and 210 F (98.9C). If
the pour point is between 70F (21C) and 90F (32C), the lower temperature should
be 122F (50.0C). For pour points between 90F (32C) and 120F (49C), the lower
temperature should be 150F (65.6C).
D. Carbon Residue
Ramsbottom carbon residue (ASTM D 524) is preferred as more accurate. If the
Conradson method(ASTM D 189) is used, the results should be converted to
Ramsbottom (see D 524).
Atomic
Absorption
(GFAA)
or
Inductively
Coupled
Plasma-Mass
maximum solution temperature. There is no standard method for wax separation, but
there are several laboratory procedures which are satisfactory. They all involve dilution
of the fuel with a poor wax solvent and then chilling to 0F or lower to separate the wax
crystals which are filtered out at low temperature.
2. Desalting by water washing will be necessary with some crude oils and is nearly
always necessary with residual oils to reduce the sodium plus potassium levels. Sodium
and potassium can cause hot corrosion of the turbine blading by sulfidation attack at the
operating temperatures of the turbine. Sodium and potassium can also contribute to
turbine fouling. Desalting is accomplished by mixing the fuel with 3% to 10% potable
water to extract the soluble salts, followed by separation of the salt- laden water by
centrifugation or electrostatic coalescence. Washing also removes some of the
calcium depending on the specific chemical nature of the calcium compounds. Lead is
not removed by water washing.
3. Vanadium can also cause hot corrosion of the turbine blading, but it is not removed by
water washing because it is present in the fuel in a complex oil-soluble form. The
corrosive action can be inhibited by adding an approved magnesium additive to the fuel
to provide a minimum 3 to 1 weight ratio of magnesium to vanadium. It is also
recommended that this ratio not exceed 3.5 to 1 in order to minimize deposition.
79
: up to 3,0 bar g
Operation Voltage/lnfeed
50Hz :!::.2%
Control Voltage
: ~230V AC
Hardness as CaC03
pH-value
: 6,5 - 7,5
Chloride ions
80
Na+K content
: Max. 50 mg/I
Suspensed matter
: Max. 50 mg/I
Particle size
: Max. 50 um
: >OC / ambient
: min. 9,5 mvh
Wash Water Consumption : Normal 3,7 - 5,6 m3/h, max. 9,3 m3/h
: 66oC
: 3.5
82
83
: up to 3,0 bar g
: up to 3,0 bar g
Control Voltage
: ~230V AC
Hardness as CaC03
pH-value
: 6,5 - 7,5
Chloride ions
Na+K content
: Max. 50 mg/I
Suspensed matter
: Max. 50 mg/I
Particle size
: Max. 50 um
: >OC / ambient
: min. 9,5 mvh
Wash Water Consumption : Normal 3,7 - 5,6 m3/h, max. 9,3 m3/h
84
Required Oil Type and Viscosity Grade ISO VG 32 The required turbine-generator
operating oil is a hydrocarbon-based turbine oil or combined cycle oil, of ISO Viscosity
Grade 32 meeting the included new oil property requirements. For special high
temperature applications ISO Viscosity Grade 46 may be recommended.
b.
Steam Turbine Oil versus Gas Turbine Oil Steam turbine oils are formulated for
oxidation resistance in the presence of relatively large amounts of water, for rust
resistance. Premium steam turbine oils have higher oxidation stability measurements
(Turbine Oil Stability Test (TOST)>3500 hrs.),
Combined cycle oils are formulated to provide the high temperature thermal stability
and oxidation resistance necessary for gas turbine service with the moisture tolerance
and rust inhibitors required in steam turbine service. Combined cycle turbine oil properties
are characterized by very high oxidation stability test measurements (TOST>6000 hrs.),
and low initial acidity (Neutralization Value<0.1). These oils are more costly than
conventional or premium grade steam turbine oils; however, they provide the equipment
owner an acceptable means to utilize common oil in single shaft steam and gas
applications.
VALUE
380 SSU
3.7.1 Components
Boiler
Superheater
Steam Separator
Deaerator
Blowdown Tank
Silencer
Feedwater Treatment
pressure jet
steam atomizing
86
Accessory specification:
Name = Burner
Type= RP-1600ME
87
CHAPTER 04
CALCULATIONS
88
Calculations:
Compressor (1-2s-2)
Inlet pressure = P1 = Atmospheric pressure differential pressure
= 1.0092 0.00526
= 1.004 bar
T2 = 522.87 K
Turbine (3 4)
T3 / T4 = [P3 / P4] g 1/ g
90
T3 = 1046.92 K
T4 = 682.92 K
As,
Turbine power output = (Ma + Mf) x Cpg x (T3 T4)
Compressor power output = Ma x Cpa x (T2 T1)
So,
Net power output = Turbine power output Compressor power input
91
= 519934.11 KWatt.
= 95400 / 519934.11
= 18.36 %
Assumptions:
pressure.
93
Calculations:
1-
Evaporator
Pressure = P6 = 71 bar
Outlet temperature = T6 = 285 oC
Saturation temperature at 71 bar = 286.76 oC
Degree of super-heat = 1.808 oC
4.
Super-heater
5.
Turbine
94
= h1 h2
h1 h2
Putting all values, we get
0.85 =
4421.6 h2
4421.6 3304.3
h2 = 3471.9 KJ/Kg
4.
Condenser
5. Feed Pump
h4 = 289.6 KJ/Kg.K
Degree of sub cooling = 178.8 oC
Turbine work output = h1 h2
= 4421.6 3471.90
= 949.7Kj/Kg
Feed pump work input = h4 h3
= 289.6 285.93
= 3.647Kj/Kg
Net work output = Turbine work Feed pump work
= 949.7 3.647
= 946.053 KJ/Kg
96
6. Heat supplied
Heat supplied = h1 h4
=4421.6 289.6
= 3232.02 KJ/Kg
Total power produced = Net power of G.T unit no.1 + Net power of G.T unit no.2 + Net
power of G.T unit no.3+ Net Power of HRSG unit no.1 + Net power of HRSG unit no.2+
Net power of HRSG unit no.3
=95.4 x 1000 + 95.4x 1000 + 95.4x 1000 + 12.556 x 946.053 +
12.722 x 947.608
= 59933.7 KW
= 59.934 MW
Total heat supplied = Heat supplied in G.T unit no.5 + Heat supplied in G.T unit no.8
= 131992.3 + 108343.2
= 240335.5 KW
= 240.335 MW
Overall efficiency of combined cycle = c.c = Net power produced / Total heat supplied
= 59.934 / 240.335
97
= 24.94 %
Efficiency without installing the combined cycle = (15+ 12) / 240.335
= 17.98%
% age increase in the efficiency by installing combined cycle = (24.94 12.98) / 17.98
= 54.5 %
98
CHAPTER 05
INTODUCTION
Our objective, carrying out THE EFFICIENCY IMPROVEMENT OF THE COMBINED CYCLE
POWER PLANT NANDIPUR.
analysis shows the energy loss in each component of the two cycles, (gas cycle and steam
cycle). In this chapter we have tried to find and investigate the factors and causes of these
loses three major components of the gas turbine cycle namely;
1.
Compressor
2.
Combustion-Chamber
3.
Turbine
99
Due to excessive amount of dust particles sticking the air filters, most of the filters are
choked which do not allow any air to be sucked in. This is the first main problem in the
combined cycle power plant at Nandipur.
In combined cycle power plant at Nandipur, there are several other factors, which
cause the pressure drop across air filter.
Remedy:
1.
There are several other unavoidable factors that cause the pressure drop across the air
filters. As we can control the land conditions but the atmospheric conditions are out of
our control, so there must be proper alternate to compensate the drop in pressure or
pressure loss.
If we employ an inlet diffuser duct before the air filters, this would increase the
pressure of the incoming air from the atmosphere. Now when this increase pressure air
passes through the air filters, pressure drop takes place, but after this drop the air pressure
is still high enough than the pressure in case of no inlet diffuser duct. This act would
increase the plant efficiency.
2.
After passing through the air filters, air is directed towards the compressor through some
pipe or duct. If this pipe or duct is given diffuser shape, the pressure of the air can be
increased at the inlet of the compressor, which would ultimately decrease the compressor
work input increasing the efficiency of the plant.
100
Comparison:
If the diffuser duct is placed before the air filters, a large area is required to install
it for required pressure increment. Also if the area is provided, there would be difficulties
in replacing the filters after service. So the placing diffuser after air filters is a better
choice if the provision of replacement is given in the plant.
1.
base load plants to operate with cold weather performance, at site temperature of 100 oF
and higher.
Remarks:
Such a system is not practical at our plant since the unit mainly operates as a
supporting unit that runs during the dry winter seasons, when the inlet air temperature is
not so high.
2.
Evaporative Cooling
As the name Evaporative Cooling implies, water is sprayed into the air inlet to
the gas turbine, as the water evaporates the air is cooled since it provides the heat of
vaporization. However, there is a limit to the air-cooling possible by this method. The
theoretical limit is the wet bulb temperature of the air. The practical limit is about 5oF
101
above the wet bulb temperature. Experience shows that when the approach temperature is
less than 5oF, water droplets carryover into the compressor, which damages the
compressor blades. And additional advantage of evaporative cooling is that mass flow
rate increases due to two reasons; firstly due to the drop in temperature of the air
increases its density, and secondly water spraying increases the water vapor content of air
which its density and thereby the work output.
Remarks:
Although the compression ratio of the unit is improved, an excess of water
droplets can corrode the compressor blade coating and hence change their relative angle.
This limits the application of this method.
When the compression is performed in two stages with an intercooler between the
stages, then the work input of a given pressure ratio and mass flow is reduced. The work
input required is a minimum when the pressure ratio in each stage is the same, and when
the temperature of the air is lowered in the intercooler back to the value at inlet to the
unit.
Work Ratio = (Work of Expansion Work of compression)/ Work of Expansion
It follows that when the compressor work input is reduced then the work ratio is
increased. However, the heat supplied when inter cooling is used is greater than with no
inter cooling. Although the net work output is increased by inter cooling it is found in
general that the increase in the heat to be supplied causes the thermal efficiency to
decrease. It will be shown late that this disadvantage is offset when a heat exchanger is
also used.
In gas turbine cycles that have regenerator, water injection is more beneficial if it
is injected between the compressor and the regenerator. With water injection the
compressed air is cooled at nearly constant pressure by the evaporating water. The cooled
compressed air is then preheated in the regenerator.
103
Remedy
Ignition delay can be minimized by increasing the compression ratio, as the plant
under consideration has been designed for compression ratio 12.65 but unit no.1 is giving
quite less compression ratio, so proper checking of that unit must be taken out to improve
the current situation. Moreover the air temperature entering the combustion chamber
must be high enough, for this we have to use a heat exchanger after compressor, which is
utilizing a part of exhaust gases from the turbine unit. Also heat transfer from the
combustion chamber to the surrounding must be reduced, the greater the heat transfer
lesser would be the temperature inside the combustion chamber and more and more
would be the ignition delay. For this purpose we have to use good insulation to prevent
the heat transfer from the combustion chamber. We can also reduce the ignition delay by
using the fuels having high octane number.
In the discussed gas turbine unit the designed air fuel ratio is 15/1 but the actual
air fuel is about 12/1 this means that the diameter of the fuel nozzle has been increased.
This results in incomplete combustion and relatively less temperature generation in the
combustion chamber. As we know that the efficiency of the gas turbine power plant
depends on the peak temperature, due to incomplete combustion lesser temperature gives
rise to lower efficiency.
1.
chamber is to make use of electronic fuel injection system. As this system would allow a
calculated amount of fuel spray in the combustion chamber, reducing the probability of
disturbing the air fuel ratio.
2.
minimize the by products of the combustion along with the unburned particles, as they
would stick to the interior of the plant causing friction and blockage. This would decrease
the efficiency of the plant with the passage of time. We can reduce these unburned
hydrocarbons by employing a thermal reactor after the combustion chamber. The
function of a thermal reactor is to oxidize the unburned hydrocarbons produced as a result
of incomplete combustion. For oxidation purpose we need air supply and relatively high
temperature. As temperature after combustion is high enough so with the pressure of air,
these unburned hydrocarbons oxidize.
105
Drawback
Thermal reactor use a large space, so can use thermal reactor only where there is
an enough space provided.
REMEDY
1.
Fuel Purification
Fuel to be used in combustion must be purified. This decreases the tendency of
2.
adequate mixture and would not disturb the air fuel ratio.
3.
106
In Nandipur power project, due to lack of maintenance the pressure drop across
the combustion chamber is about 10% which is quite high and proves negative to the
efficiency of the plant. The pressure drop in the unit No.1 is the most efficient in
comparison with the others.
Remedy
Proper inspection and maintenance would give better results. There must be
proper cleaning of the combustion chamber interior; also some intelligent designs must
be used to reduce that problem. Some high temperature resistance materials should be
used to resist more temperature.
107
However, work ratio is improved by reheating but the thermal efficiency appears
to decrease. As the exhaust gas temperatures are high, so by using that heat effectively in
combined cycle or by a heat exchanger, the thermal efficiency can be increased.
Remarks:
The greater the number of reheats and inter cooling stages, the higher the
efficiency. However, this is attained at the cost of capital investment and size of the plant.
108
The design of the plant should be optimized, with considerations given to capital versus
operating expenses and to size.
Another limitation with turbine reheat is that air pollution increases, as greater
amount of fuel has to be burned. Further, additional fuel burning requires greater amount
of oxygen, which must be supplied through an auxiliary system, which might be costly.
109
Suggestions
Today it is possible to manufacture materials with regulatory arrayed crystal
structures. The development of ceramic materials is playing a particularly significant role
in this field. Ceramic coatings, for example can be used as thermal insulation on blades.
In combustion chamber, solid ceramic heat shields are already in use as thermal
insulations.
Suggestions
To avoid this temperature drop and the resultant power loss, some other means of
cooling should be provided.
Suggestions
To minimize these heat losses, arrangements should be made for adequate lagging
of the shell, which should not hamper the maintenance works.
110
Remarks
These temperature variations should be minimized. The temperature of exhaust gases
leaving the HRSG also depends upon the temperature of gases leaving the gas turbine. So it is
very important to control the turbine exhaust temperature.
111
Remarks
In C.C.P.P Nandipur, Three HRSGs are installed on the three gas turbine units. The
steam plant is not operated for the whole year as it is used as supporting unit. In order to run the
steam turbine, at least two gas turbine units should be in operation. Otherwise the heat from a
single unit cannot produce the required degree of superheating to run the steam turbine. So in out
case, the installation of supplementary firing equipment will make the system more flexible and
it may also be used as base load unit.
Remarks
Although the feed water used in steam cycle is treated and dematerialized but the quality
that water is not good enough to avoid contaminants. The quality of feed water used in steam
plant should be improved.
112
The contaminants present in feed water result in more and more residues in the boiler
drum as the boiler water is continuously vaporized and densified (the contaminants carried over
by steam is relatively less). So this causes a false water level. When the water level is higher than
the nominal level, the volume of steam space is decreased. So the steam carries over more water
droplets. Because of high steam speed, the steam stays short time, so the water droplets content
of the steam is not separated completely. This affects the water quality.
Remarks
The poor quality feed water increases the HP drum level so the quality of feed water
The discharge the dense sediments from the HP boiler drum, blow down is required in
C.C.P.P Nandipur intermittent blow down is carrying on in which the deposits in boiler water are
discharged intermittently. We recommend the use of continuous blow down in which the dense
sediments are discharge continuously and hence is more effective. The continuous blow down
option is also carried out. The intermittent. Blow down is carried out after 24 hours and it takes
one minute. We also recommend an increase in the number of intermittent blow downs.
113
condition. One reason of this superheating could be the friction offered by evaporation tubes to
steam flow thus increasing the temperature than the design temperature.
Remarks
In order to remove the soot layer, soot blowing is required. In soot blowing, steam under
high pressure is blown and passed through the HRSG which clears the soot layer. It is suggested
that soot blowing should be done quite often.
114
Remarks
The insulation of turbine shell needs to be increased. This can be done either by replacing
the insulation material or by increasing the thickness of insulating material.
Friction Loss
There is a frictional resistance between the steam and the sides of a nozzle, a loss due to
impact as the steam enters the moving blades, and eddying and fluid friction in the blades. If dry
115
saturated steam is used it will be wet after expansion and the presence of the moisture will
greatly increases the friction. The fluid friction also increases with the increases in fluid velocity,
which is reduced by compounding. The friction offered by turbine blades reduces the isentropic
efficiency of the turbine so all these losses needs to be minimized.
Remarks
In 425MW C.C.P.P Nandipur, the steam turbine comprises of 2 stages i.e. H.P and L.P
turbine with no reheating between these stags. The heat energy available in HRSG exhaust in not
that much to reheat the steam after supplementary in 1st turbine. If the design of HRSG is
changed and supplementary firing equipment is provided then reheating of steam will increase
the efficiency of the plant.
116
reduced because air offers high resistance to heat flow. This required more quantity of cooling
water to maintain heat transfer rate.
The pressure of air lowers the partial pressure of steam and its corresponding
temperature. The latent heat of steam increases at low pressure. Therefore more quantity of water
is required to condense one kg of steam as the quantity of latent heat to be removed is more.
Remarks
In C.C.P.P Gujranwala, the problem of air mixing with feed water was observed. This
problem may be due to the following reasons.
Air may enter the condenser through various joists of different parts where internal
pressure is less than atmospheric pressure. The feed water in HRSG may contain some air in it.
Therefore, the exhaust steam may carry some amount of air along with it even after passing
through the desecrator.
Remarks
The insulation of cooling water pipes should be improved and the storage well should be
insulated from direct sun radiations. In this way, the temperature of water entering the condenser
will decrease and more heat transfer will take place.
117
CHAPTER 06
CONCLUSION
The combination of the gas turbine Brayton Cycle and the steam power system Rankine Cycle
complement each other to form efficient combined-cycles. The Brayton Cycle has high source
temperature and rejects heat at a temperature that is conveniently used as the energy source for
the Rankine Cycle. The most commonly used working fluids for combined cycles are air and
steam. Other working fluids (organic fluids, potassium vapor, mercury vapor, and others) have
been applied on a limited scale. Combined-cycle systems that utilize steam and airworking
fluids have achieved widespread commercial application due to:
Heat rejection from the Brayton Cycle (gas turbine) at a temperature that can be utilized in a
simple and efficient manner.
Working fluids (water and air) that is readily available, inexpensive, and non-toxic.
After going through the past review of research the effects of major operating parameters can
be summarized as follows:
1. The turbine inlet temperature significantly affects the performance of combined cycle.
It should be kept on higher side for minimizing the energy losses.
118
3. The decrease in pinch point temperature the more heat transfer in steam bottoming cycle
thus improving the combined cycle performance.
5. The increase in number of pressure levels improves the combined cycle performance.
6. There are miscellaneous configurations which also improves the combined cycle
performance.
119
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