Combined Cycle Power Plant Combined Cycle

Operation Power Plant

Thermodynamic
Principles

Training Lesson

ALSTOM (Switzerland) Ltd ABCD

 CCPP Combined Cycle Power Plant
ABCD Operation Thermodynamic Principles

We reserve all rights in this document and in the information contained therein.
Reproduction, use or disclosure to third parties without express authority is strictly
forbidden.
Copyright© by ALSTOM (Switzerland) Ltd 2007

This is a training lesson. It provides overall information about the specific system
only.
To understand the operation concept in detail the project specific documents as
defined in the document reference section have to be included together with this
lesson.
All mentioned / attached values and settings are for information only. Typical
values are used to clarify particular subjects. Settings furthermore are subject to
change site specifically during commissioning.
For actual values please refer to the final plant specific
Operation & Maintenance Documentation.

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 CCPP Combined Cycle Power Plant
ABCD Operation Thermodynamic Principles

Table of Contents

Document Reference ........................................................................................................................... 4

Typical Documents ........................................................................................................................... 4
O&M Documentation ....................................................................................................................... 4
Lesson Objectives................................................................................................................................ 5
The Combined Cycle Process ............................................................................................................... 6
Efficiency of the Combined-Cycle Plant.............................................................................................. 8
Efficiency of Combined Cycles without Supplementary Firing in the HRSG ......................................... 10
Exercises Thermodynamic Principles ................................................................................................... 16
Gas Turbine Process Efficiency ........................................................................................................ 16
Steam Turbine Process Efficiency ..................................................................................................... 17
Summary .......................................................................................................................................... 18
Objectives Review .......................................................................................................................... 18

Table of Figures

Figure 1: Temperature/Entropy Diagrams for Various Cycles ................................................................ 8

Figure 2: The Efficiency of a Simple Cycle Gas Turbine with Single Stage Combustion as a Function
of Turbine Inlet Temperature (TIT) and the Turbine Exhaust Temperature............................... 12
Figure 3: The Efficiency of a Combined-Cycle with a single Stage Combustion Gas Turbine as a
Function of the Turbine Inlet Temperature (TIT) and the Turbine Exhaust Temperature............ 13
Figure 4: The Efficiency of a Simple Cycle Gas Turbine with Sequential Combustion as a Function of
the Turbine Inlet Temperature (TIT) and the Turbine Exhaust Temperature ............................. 14
Figure 5: The Efficiency of a Combined-Cycle with a Sequential Combustion Gas Turbine as a
Function of the Turbine Inlet Temperature (TIT) and the Turbine Exhaust Temperature............ 15

Table of Tables

Table 1: Thermodynamic Comparison of Gas Turbine, Steam Turbine and Combined-Cycle Processes .. 7
Table 2: Allowable Reduction in Steam Process Efficiency as a Function of Gas Turbine Efficiency
(ηST = 0.3)......................................................................................................................... 11

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 CCPP Combined Cycle Power Plant
ABCD Operation Thermodynamic Principles

Document Reference
Typical Documents

Typical documents clarify the aspects described in this lesson which may not show
project specific contents, therefore deviations to the specific installation are possible.
All typical documents are referenced in the lesson and clearly identified.

O&M Documentation

O&M Documents are plant specific and form an important part of each training
course. The training material includes the most relevant O&M Documents and
provides a basis for exercises and personal notes, markings, etc. The most relevant
documents for the operation training are as follows:
• Design Heat Balance and Off-Design Heat Balances
• P&IDs with legend
• System descriptions
• Operating instructions
• Operating diagrams
• Instrument lists
• Set point lists

The O&M Documents are separated into:

• System specific documents
• Overall plant specific documents
The system specific documents are attached to each lesson, whereas the overall
plant specific documents are found in separate sections at the end of the training
manual.

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 CCPP Combined Cycle Power Plant
ABCD Operation Thermodynamic Principles

Lesson Objectives

Upon completion of this lesson, the trainee is able to:

• Summarize the carnot efficiency and the differences to real energy cycles

• Explain the net efficiency of the combined cycle power plant

• Draw and explain a gas turbine process diagram with a bottoming cycle to
show a combined cycle plant process. Label its most important parameters.

• Summarize the sequential combustion process in a temperature – entropy

diagram and the technical impacts on the machine itself.

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 CCPP Combined Cycle Power Plant
ABCD Operation Thermodynamic Principles

The Combined Cycle Process

The Carnot The Carnot efficiency is the efficiency of an ideal thermal process:
Efficiency TE − TA
Equation ηc = Equation 1
TE
Where:
ηc = Carnot efficiency
TE = Temperature of the Energy supplied, (K)
TA = Ambient Temperature, (K)

Energetic and Naturally, the efficiencies of real processes are lower since there are losses
Exergetic Losses involved. A distinction is drawn between the following:
• Energetic losses
• Exergetic losses
Energetic losses are mainly heat losses, which result in the loss of energy from the
process. Exergetic losses are internal losses caused by irreversible processes in
accordance with the second law of thermodynamics.

Improving the The process efficiency can be improved by raising the maximum temperature in the
Process cycle, releasing the waste heat at a lower temperature, or by improving the process
Efficiency to minimize the internal exergetic losses.
The interest in combined-cycles arises from these considerations. By its nature, no
single-cycle can match all of these improvements extent. It thus is reasonable to
combine two cycles as follows:
• The topping cycle with high process temperatures
• The bottoming cycle with a good “cold end”

In a simple-cycle gas turbine, attainable process temperatures are high because

energy is supplied directly to the cycle without heat exchange. The exhaust heat
temperature, however, is also high. In the steam cycle, the maximum temperature is
much lower than the gas turbine process, but the exhaust heat is returned to the
environment at a low temperature. As illustrated in Table 1 (Page 7), combining a
gas turbine and a steam turbine thus offers the best possible basis for a high
efficiency thermal process.

(Continued next page)

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ABCD Operation Thermodynamic Principles

The Combined Cycle Process (continued)

Carnot The last line in the table shows the Carnot efficiencies of the various processes (i.e.,
Efficiencies the efficiencies that would be attainable if the processes took place without internal
exergetic losses). Although not realistic, this figure can be used as an indicator of
the quality of a thermal process. The value shown demonstrates the effectiveness of
the combined-cycle power plant when compared to a single process cycle. Even a
sophisticated, supercritical conventional reheat steam turbine power plant has a
Carnot efficiency around 20 points lower than that of a good combined-cycle plant.

Gas Turbine Steam Turbine Combined Cycle

Power Plant Power Plant Power Plant

Average temperature of 1’000 – 1’350 640 – 700 1’000 – 1’350

heat supplied K (°F) (1’800 – 2’430) (1’152 – 1’260) (1’800 – 2’430)

Average temperature of 550 – 600 300 – 350 300 – 350

dissipated heat K (°F) (900 – 1’080) (540 – 630) (540 – 630)

Carnot efficiency % 45 – 50 45 – 57 65 - 78

Table 1: Thermodynamic Comparison

of Gas Turbine, Steam Turbine and Combined-Cycle Processes

For combined-cycle power plants, actual efficiencies are around 75% of the Carnot
Efficiency, whereas for conventional steam power plants, this figure is around 55%.
The differences between the actual efficiencies attained by a combined-cycle power
plant and the other processes are therefore less then those illustrated in Table 1.
The relatively larger drop in the combined-cycle efficiency is caused by higher
internal energy losses due to the temperature differential for exchanging heat
between the gas turbine exhaust and the water/steam cycle.

As shown in Table 1 – which compares the temperature/entropy diagrams of the

processes – the combined-cycle best utilises the temperature differential in the heat
supplied despite an additional exergetic loss between the gas and the steam
process.

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ABCD Operation Thermodynamic Principles

Efficiency of the Combined-Cycle Plant

It has been assumed until now that fuel energy is supplied to the cycle only in the
gas turbine. There are also combined-cycle installations with additional firing in the
heat recovery steam generator (HRSG), in which a portion of the heat is supplied
directly to the steam process.

Q+ Q+
1530k

900K
Q+
Temperature

Temperature
800K 840K

700K

590K

288K Q- 300K
Q-

Entropy Entropy
Figure A Figure B

Q+ Q+
1530K

Q+
Temperature

Temperature

840K
900K
840K
800K
700K
630K
590K

300K 300K
Q- Q-
Q+ 288K

Entropy Entropy
Figure C Figure D

A Gas turbine with and without sequential combustion

B Steam turbine without reheat

C Steam turbine with reheat

D Combined cycle showing gas turbine topping

CSXA401843.cdr

Figure 1: Temperature/Entropy Diagrams for Various Cycles

(Continued next page)

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 CCPP Combined Cycle Power Plant
ABCD Operation Thermodynamic Principles

Efficiency of the Combined-Cycle Plant (continued)

General The general definition of the electrical efficiency of a combined-cycle plant is as

Definition follows:
PGT + PST
ηcc = Equation 2
QGT + QSF
Where:
PGT = Gas turbine output
PST = Steam turbine output
QGT = Gas turbine fuel input
QSF = Additional / supplementary firing fuel input

Gross Efficiency This equation shows the gross efficiency which does not include station service
power consumption and electrical losses, also called auxiliary consumption, PAUX . If
station auxiliary consumption is considered, the net efficiency of the combined-cycle
is given by:
PGT + PST − PAUX
ηcc,net = Equation 3
QGT + QSF

In general, the efficiencies of the simple cycle gas and steam turbine processes are
as follows:
PGT
ηGT = Equation 4
QGT
PST
ηST = Equation 5
QGT.Exh + QSF
Where:
QGT.Esx ≅ QGT (1 - ηGT) Equation 6

Combining these two equations yields:

PST
ηST = Equation 7
QGT(1 − ηGT) + QSF

This equation expresses the steam process efficiency of the combined-cycle.

If there is no supplementary firing in the HRSG, then equations 1 through 7 are

simplified by eliminating QSF, (QSF = 0). In view of the earlier considerations, it is
generally better to burn the fuel directly in a modern gas turbine rather than in the
HRSG because the heat is supplied at a higher temperature (GT versus ST process
in Table 1). For that reason interest in supplementary firing decreases.

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ABCD Operation Thermodynamic Principles

Efficiency of Combined Cycles without Supplementary Firing in the HRSG

Efficiency The most common and straightforward type of combined-cycle supplies fuel in the
Equations gas turbine combustion chamber without additional heat supplied in the HRSG. By
substituting equations 4 and 7 into equation 2:
ηGT ⋅ QGT + ηST ⋅ QGT(1 − ηGT)
ηcc = = ηGT + ηST (1 - ηGT) Equation 8
QGT
Differentiation estimates the effect that a change in the gas turbine efficiency has on
overall efficiency:
δηST
δηcc = 1 + (1 - ηGT) - ηST Equation 9
δηGT
Increasing the gas turbine efficiency improves the overall efficiency only if:
δηcc
>0 Equation 10
δηGT
From equation 9:
δηST 1 − ηST
- < Equation 11
δηGT 1 − ηGT

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ABCD Operation Thermodynamic Principles

Effects by Improving the gas turbine efficiency is helpful only if it does not cause a significant
Increasing GT drop in the efficiency of the steam process. Table 2 shows that increasing the gas
Efficiency turbine efficiency, decreases the steam process efficiency. In order to keep the same
overall combined cycle efficiency, the gas turbine efficiency must be raised from
30 to 35% if the steam turbine efficiency is reduced from 30 to 27.8% (30/1.08).
However, under some circumstances both efficiencies can be raised at the same
time. A gas turbine with maximum efficiency does not always provide an optimum
combined-cycle plant.

For example: For a gas turbine with single-stage combustion at constant turbine
inlet temperature, a very high-pressure ratio attains a higher efficiency than a gas
turbine with a moderate-pressure ratio. However, the efficiency of the combined-
cycle plant with the second machine is normally better because the steam turbine
operates far more efficiently with the higher exhaust gas temperature.

ηGT 0.3 0.35 0.4

δηST
- 1.0 1.08 1.17
δηGT

Table 2: Allowable Reduction in Steam Process Efficiency

as a Function of Gas Turbine Efficiency (ηST = 0.3)

(Continued next page)

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ABCD Operation Thermodynamic Principles

Efficiency of Combined Cycles without Supplementary Firing in the HRSG (continued)

Efficiency of
45
Simple Cycle GT TIT - 1400 °C
TIT - 1200 °C
TIT - 1000 °C
Gross Gas Turbine Efficiency, LHV (%)

40

35

30

25
300 400 500 600 700 800

Gas Turbine Exhaust Temperature (°C) CSXA401789.cdr

Figure 2: The Efficiency of a Simple Cycle Gas Turbine with Single Stage Combustion
as a Function of Turbine Inlet Temperature (TIT) and the Turbine Exhaust Temperature

Figure 2 demonstrates the efficiency of the simple-cycle gas turbine with single
stage combustion as a function of the turbine inlet and exhaust gas temperatures.
The maximum efficiency is reached when the exhaust gas temperatures are quite
low. In this case a low exhaust temperature is equivalent to a high-pressure ratio.

(Continued next page)

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ABCD Operation Thermodynamic Principles

Efficiency of Combined Cycles without Supplementary Firing in the HRSG (continued)

Efficiency of a Figure 3 shows the overall efficiency of the combined-cycle based on the same gas
CCPP Single turbine. Compared to Figure 2, the optimum point has shifted toward higher
Stage exhaust temperatures from the gas turbine, which indicates an over-proportional
Combustion GT improvement of the water/steam cycle compared to the loss in gas turbine
efficiency. For economic reasons, current gas turbines are generally optimized with
respect to maximum power density (output per unit air flow) rather than efficiency.
Often, this optimum coincides fairly accurately with the optimum efficiency of the
combined-cycle plant. As a result, most of the modern gas turbines are optimally
suited for combined-cycle installations.

65
Gross Combined Cycle Efficiency, LHV (%)

60

55

50

45

40
TIT - 1400 °C
TIT - 1200 °C
35
TIT - 1000 °C

30

25

200 300 400 500 600 700

Gas Turbine Exhaust Temperature (°C) CSXA401790.cdr

Figure 3: The Efficiency of a Combined-Cycle with a single Stage Combustion Gas Turbine
as a Function of the Turbine Inlet Temperature (TIT) and the Turbine Exhaust Temperature

More complicated gas turbines (i.e., with intermediate cooling in the compressor or
recuperator) are less suitable for applications in a combined-cycle plant. They
normally have a high simple-cycle efficiency combined with a low exhaust gas
temperature, so that the efficiency of the water/steam cycle is accordingly lower.
These machines are more suitable for simple-cycle operation.

(Continued next page)

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ABCD Operation Thermodynamic Principles

Efficiency of Combined Cycles without Supplementary Firing in the HRSG (continued)

Efficiency of a The effects of a high-pressure ratio and low combined-cycle efficiency can be
Simple Cycle GT uncoupled if the gas turbine is designed with sequential combustion- (air, upon
with Sequential leaving the compressor, passes through the first combustion chamber and expands
Combustion in the first turbine stage before final combustion and expansion). Gas turbines with
sequential combustion have practically the same simple-cycle efficiencies as single-
combustion gas turbines at the same overall pressure ratio and turbine inlet
temperature.

45
Gross Gas Turbine Efficiency, LHV (%)

40

35

30 TIT - 1400 °C
TIT - 1200 °C
TIT - 1000 °C

25
300 400 500 600 700 800

Gas Turbine Exhaust Temperature (°C) CSXA401791.cdr

Figure 4: The Efficiency of a Simple Cycle Gas Turbine with Sequential Combustion
as a Function of the Turbine Inlet Temperature (TIT) and the Turbine Exhaust Temperature

For comparison, the same curves shown in figure 2 and 3 are shown for gas
turbines with sequential combustion in figure 4 and 5. Figure 4 shows almost the
same optimum simple-cycle gas turbine efficiency level for the same gas turbine
inlet temperatures (TIT). However, the exhaust gas temperatures are substantially
higher, clearly improving the combined-cycle efficiency levels of Figure 5 compared
to 3. As for Figure 2, a low exhaust gas temperature is equivalent to a high-
pressure ratio of the sequential part (low-pressure part) of the gas turbine. For
consistency, the pressure ratio of the high-pressure turbine is kept constant at
1.7 / 1.

(Continued next page)

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ABCD Operation Thermodynamic Principles

Efficiency of Combined Cycles without Supplementary Firing in the HRSG (continued)

Efficiency of a The reheat process of a sequentially fired gas turbine provides an advantages over
CCPP with single combustion gas turbines. This gives the ideal base for improved combined-
Sequential cycle efficiencies, which also fits well to the Carnot comparison.
Combustion GT

65
Gross Gas Turbine Efficiency, LHV (%)

60

55

50

TIT - 1400 °C
45 TIT - 1200 °C
TIT - 1000 °C

40
300 400 500 600 700 800

Gas Turbine Exhaust Temperature (°C) CSXA401792.cdr

Figure 5: The Efficiency of a Combined-Cycle with a Sequential Combustion Gas Turbine

as a Function of the Turbine Inlet Temperature (TIT) and the Turbine Exhaust Temperature

In summary, the optimum gas turbine for simple-cycle and the optimum gas turbine
for combined-cycle are not the same. The gas turbine with the highest efficiency
does not necessarily produce the best overall efficiency of the combined-cycle plant.
The type of gas turbine (i.e., gas turbine concept) and turbine inlet temperature are
important factors. The gas turbine is generally a “standard machine” and must
therefore be optimized by the manufacturer for its main application (i.e., combined-
cycle or simple-cycle).

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ABCD Operation Thermodynamic Principles

Exercises Thermodynamic Principles

Gas Turbine Process Efficiency

Exercise Task Define and evaluate your gas turbine process as follows:
Draw a Carnot diagram of your gas turbine process and calculate it’s actual
efficiency using the Carnot equation.
Calculate the efficiency of your gas turbine using the gross electrical efficiency
equation.
Explain the efficiency difference between Carnot and your real process.

Exercise Aids • Guarantee Heat Balance

• Gas turbine set point list

Group, • Group work with max. 4 trainees per group

Time Frame, • 15 minutes
Presentation
• Group presentation in front of class.

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ABCD Operation Thermodynamic Principles

Steam Turbine Process Efficiency

Exercise Task Define and evaluate your steam turbine process as follows:
Draw a Carnot diagram of your steam turbine process and calculate it’s actual
efficiency using the Carnot equation.
Calculate the efficiency of your steam turbine process using the gross electrical
efficiency equation.
Explain the efficiency difference between Carnot and your real process.

Exercise Aids • Guarantee Heat balance

Group, • Group work with max. 4 trainees per group

Time Frame, • 15 minutes
Presentation
• Group presentation in front of class.

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ABCD Operation Thermodynamic Principles

Summary
Objectives Review

Carefully review the objectives stated on page 5 of this lesson together with the Test
Questions for Verification of Learning Progress. Note that this lesson is not complete
without the system specific and overall plant Operation & Maintenance
Documentation.

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