Natural Gas
from GAIL
Gas Booster
Compressor
HRSG
burners
Gas
Power to TNEB generator Exhaust Gas
Turbine
Steam
Steam
generator Turbine Air Cooled Condenser
pump
A combined cycle power plant consists of :
A gas turbine-generator (GTG)
A heat recovery steam generator (HRSG) and
A steam turbine-generator (STG)
Gas turbine generates power by the
combustion of natural gas or any liquid fuel
The exhaust gas from GT is fed into a (HRSG)
In the HRSG feed water is converted into
super heated steam
This steam is used to run the steam turbine
TYPICAL COMBINED CYCLE
POWER PLANT
ARRANGEMENT
GAS TURBINE
A machine which transfers fuel energy into mechanical energy
AIR FUEL TO EXHAUST
SD LOAD
Starting
device HEAT WORK
COMPRESSION ADDITION EXPANSION DONE
By heating up compressed air expanding it in nozzles
mechanical/rotational energy is obtained
GAS TURBINE CYCLE
THE BRAYTON CYCLE
The thermodynamic cycle upon which all gas turbines operate is called the
Brayton cycle. The temperature-entropy (TS) diagram for this cycle is shown
above
Path 1 to 2 represents the compression occurring in the compressor
Path 2 to 3 represents the constant-pressure addition of heat in the
combustion systems
Path 3 to 4 represents the expansion occurring in the turbine.
The path from 4 back to 1 on diagrams indicates a constant-pressure cooling
process.
In the gas turbine, this cooling is done by the atmosphere, which provides
fresh, cool air at point 1 on a continuous basis in exchange for the hot gases
exhausted to the atmosphere at point 4.
THERMAL PP CYCLE
THE RANKINE CYCLE
The thermodynamic cycle upon which all thermal power plants
operate is called the Rankine cycle. The temperature-entropy
(TS) diagram for this cycle is shown above
Path 1 to 2 represents the feed pump work
Path 2 to 3 represents sensible addition of heat economiser
Path 3 to 4 represents the latent heat addition in the evaporator
section
Path 4 to 5 represents super heating at constant pressure
Path 5 to 6 represents the expansion in turbine section
Path 6 to 1 represents the latent heat rejection in condenser
COMBINED CYCLE
1300 deg C
Gas turbine
inlet temp.
TOPPING CYCLE
600 deg C BRAYTON- CYCLE
Gas turbine
exhaust temp.
540 deg C
Steam turbine
inlet temp
BOTTOMING CYCLE
RANKINE- CYCLE
Steam turbine
exhaust temp
50 deg C
Evolution of Industrial Gas Turbines
• Heavy duty gas turbines were built after World war
introduced in market in 1950s
• Earlier gas turbines were an extension of steam
turbine design having thick walled casings, large
combustors, thick airfoil blades etc
• These industrial gas turbines were rugged in operation but
low on performance, efficiencies were as low as 15%
• From 1960s to late 1980s, steam turbine based
plants were the base load providers, Gas turbines were
used for peaking power only.
• With increased demand for power, need for Gas turbine
based power plant was felt
Evolution of Industrial Gas Turbines
Powered by the need for
• Low cost electricity.
• Better Simple and Combined cycle efficiencies.
• Conformance with environmental standards
• Better availability and reliability.
• Ease of Installation and Commissioning
• Flexibility to meet various service and fuel needs
Gas Turbines
• Efficient
• Compact
• Reliable
• Eco-Friendly
• Self contained
• Light weight
• High Power Density
• Low installation time
• Quick start
• Black start Capability
Basic Components
Basic Components
Compressor
• Draws in air & compresses it
Combustion Chamber
• Fuel pumped in and ignited to burn with compressed air
Turbine
• Hot gases converted to work
• Can drive compressor & external load
COMBINED-CYCLE POWER PLANT
A Gas Turbine and a Steam Turbine
are used in combination
to achieve
greater efficiency than would be
possible independently.
Efficiency = GT Power / Fuel Energy
UNUTILIZED ENERGY IN
GT APPEARS IN THE FORM
OF
HIGH TEMPERATURE
EXHAUST GASES LEAVING
THE GAS TURBINE
THIS HEAT ENERGY CAN BE
RECOVERED BY
GENERATING
STEAM IN A BOILER CALLED
HEAT RECOVERY STEAM
GENERATOR (HRSG)
THIS HEAT RECOVERY
RESULTS IN HIGH
OVERALL
PLANT EFFICIENCY
COMBINED-CYCLE :
COUPLING OF THE TWO CYCLES
COMBINED-CYCLE
(BRAYTON CYCLE + RANKINE CYCLE)
Incorporates advantages of both the
cycles viz.
Heat Addition at High temperatures
(1000 to 1300 C) and
Heat Rejection at Low temperatures
(30 to 45 C).
Plant efficiencies as high as 58% can
be achieved in combined-cycle mode of
COMBINED-CYCLE POWER PLANTS
In modern CCPPs, the steam turbine
(which is connected downstream of the gas turbine)
generates
an additional 50 % of power
without
extra fuel having to be burnt.
The combined-cycle system
provides flexibility with features
that include:
1. High Thermal Efficiency–
Combined cycle thermal efficiency
is higher than that of other
conventional power generation
systems
2. Low Installed Cost –
Combined-cycle equipment is pre-engineered and
factory packaged to minimize installation time and
cost. All major equipment (gas turbine generator,
heat recovery steam generator [HRSG], and steam
turbine generator) is shipped to the field as
assembled and tested components.
[Link] flexibility
[Link] duty cycle
[Link] installation time
[Link] emissions-environment friendly
[Link] reliability/availability
The performance of a combined cycle power plant
depends on the performance of the following :
Gas turbine-Generator
Heat Recovery Steam Generator
Steam turbine-Generator
By lowering the condenser vacuum, the range of expansion in steam turbine increases
thus increasing the steam turbine output
Super heating the steam to a higher temperature increases the enthalpy of the steam at
the inlet of the steam turbine
Re-heating the steam after expansion in the HP turbine increases the enthalpy
Heating the feed water with extraction steam from turbine downstream stages
improves the cycle efficiency
A combined cycle power plants
performance mainly depend on the
performance of the Gas Turbine
Let us see how a gas turbine process takes
place and the factors that affect the
performance and the output
Ambient pressure
Compressor inlet air temperature
GT Speed
Relative humidity
Inlet pressure drop
Water / Steam injection
Condition of machine
Change in air flow. 101
Effects only Output.
No effect on Heat rate. 100
No change in exhaust 99
temperature.
Percentage GT Output
98
97
96
95
970 980 990 1000 1010 1020
Ambient Pressure (mbar)
Change in Air flow. 125
Change in Compressor work. 120
Exhaust gas parameters.
Percetage Power and heat rate
115
110
Power Output
105
100
Heat Rate
95
90
15 20 25 30 35 40 45 50 55
Compressor Inlet Air Temperature(C)
Change in Air flow. 108
Effect differs at varying 106
ambient temperatures. 104
102
PERCENT GAS TURBINE OUTPUT (%)
100
98 15
27
96
40
94
92
90
88
86
84
95 96 97 98 99 100 101 102 103 104
GT SPEED (%)
Change in Air flow. 105
Effect differs at varying 104
ambient temperatures.
PERCENT GAS TURBINE HEAT RATE (%)
103
102
101
100
15
27
99
40
98
95 96 97 98 99 100 101 102 103 104
GT SPEED (%)
Specific humidity. 100.3
Humid air less dense
than dry air. 100.1
15
Reduced air flow. 99.9
40
Percentage GT Output
50
Compressor work.
99.7
*
99.5
99.3
99.1
30 40 50 60 70 80 90
Relative Humidity (%)
Specific humidity. 101.5
Humid air less dense
than dry air. 101
PERCENTAGE GT HEAT RATE
Air flow.
Unavailable heat
100.5
energy.
100
99.5
15
35
40
99
30 40 50 60 70 80 90
RELATIVE HUMIDITY (%)
New And Clean Condition
O
u On-line
t
p
u
t
5% CPR-
13%
Off-line output
Time
Air Quality
Dust, oil vapour, soot.
Blade fouling,
corrosion, surface
roughness.
Reduced mass flow,
Pressure ratio.
Reduced Output.
Increased Heat rate.
Tip Clearances. 4.5
Aero foil shape. 4
Surface roughness. OUTPUT
Percent decrease in Output & Percent increase in Heat Rate
3.5
2.5
HEAT RATE
1.5
0.5
0
0 2 4 6 8 10 12 14 16
To tal GT Fired Hours x 1000
NOx. 2.25
Increased mass flow 2
through turbine. 1.75
Percentage change in Heat Rate, (%)
Increased Heat
1.5
1.25
consumption. 1 15
35
0.75
40
0.5
0.25
0
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
Water Injection (kg/hr)
NOx
Increased mass flow
5
through turbine.
Percentage change in POWER, (%)
4
Increased Heat 3
consumption. 15
35
2
40
0
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
Water injection (kg/hr)
Air flow. 4
3.5
Performance loss (%)
2.5
2
Decrease in Power (%)
1.5
Increase in Heat Rate(%)
0.5
0
0 2 4 6 8 10
Extra Inlet duct Loss
Inlet air cooling
Evaporative cooling
Inlet chilling
Steam / Water injection
Fuel heating
Frequent water washing
Peak Firing
Air enters the axial flow compressor at
point 1 at ambient conditions.
These conditions vary from day to day
and from location to location.
The change in these ambient
conditions affect the output and
performance of gas turbine
It is convenient to consider some
Gas Turbine Schematic standard conditions for comparative
purposes.
o as ISO conditions
The standard conditions used by the gas turbine industry are
Dry Bulb Temp : 15 C
Atmospheric Pressure : 1.013 bar
Relative Humidity : 60%
These are established by the International Standards
Organization (ISO)
GAS TURBINE PROCESS- COMPRESSOR AND COMBUSTION CHAMBER
Air entering the compressor at point 1 is compressed to some higher
pressure.
No heat is added; however, compression raises the air temperature .
Air at the discharge of the compressor is at a higher temperature and
pressure.
Upon leaving the compressor, air enters the combustion system at
point 2, where fuel is injected and combustion occurs.
The combustion process occurs at essentially constant pressure.
GAS TURBINE PROCESS- TURBINE SECTION
In the turbine section of the gas turbine, the energy of the hot gases
is converted to work.
Some of the work developed by the turbine is used to drive the
compressor.
The remainder is available as electrical power at generator terminals
Typically, more than 50% of the work developed by the turbine
sections is used to power the axial flow compressor
AIR FLOW
???
GAS
3 kg/sec
Generator
60 MW
AIR to FUEL RATIO-60:1
This means any slight change in the air
flow to the turbine will affect its output
180 kg/sec
1. COMPRESSOR SPEED
2. AMBIENT TEMPERATURE
3. FLOW PATH RESISTANCE
4. COMPRESSOR FOULING
5. COMPRESSOR PROTECTION
LOGIC
COMPRESSOR SPEED
Exhaust to HRSG
TO GRID
Air Flow through compressor is a function of its speed
Compressor, Turbine and Generator are connected on a single shaft
Once GTG is synchronized to GRID the speed of the compressor is
governed by the grid frequency.
Therefore any change in frequency will affect the airflow.
As per Indian grid condition the frequency is always less than 50Hz
and varying continuously leading to loss in output due to airflow
reduction
AIR INLET TEMPERATURE
Industrial gas turbines when run at constant speed are
constant-volume-flow machines.
The specific volume of air is directly proportional to the
temperature.
Because the cooled air is denser, it gives the machine a higher
air mass flow rate and pressure ratio, resulting in an increase
in output.
In combined-cycle applications there is also a small
improvement in thermal efficiency.
In Indian weather condition the ambient air temperature can
reach as high as 42 deg C during summer resulting in
reduction of air flow and hence output.
Generally a 6% increase in ambient temperature decreases
the combined cycle power output by 2.5%.
FLOW RESISTANCE From atmosphere to
compressor inlet the
air has to travel
through many
equipments installed in
the flow path
These flow path resistances
lead to pressure drop in the
inlet
There are filters installed in
the air flow path to remove
impurities. These filters gets
choked with time leading to
reduced air flow as well as
inlet pressure drop
A drop in inlet pressure leads the compressor to do more work
resulting in less net power output from turbine
Typically a 10mbar inlet pressure drop will reduce the power output
by 1.4%
COMPRESSOR FOULING
Gas turbine installations have inlet air filtration
systems to reduce or eliminate contaminants that
can damage the axial compressor or affect its
performance.
Regardless of filter efficiency, axial compressor
fouling is unavoidable and depends on
environmental conditions.
Excessive fouling of compressor blades results in
lower compressor efficiency and consequently a
loss of gas turbine performance.
Improving the air flow through gas turbine
compressor will increase its output and efficiency
Cooling the inlet air will increase the mass flow
due to increase in density.
The various methods used to cool the inlet air
are:
[Link] cooling
[Link] air chilling
[Link]
There are two concepts to enhance the
combined cycle performance
Power Augmentation
Efficiency Enhancement
Power Augmentation
Three basic methods are available for
power augmentation:
[Link] or steam injection in GT
[Link] supplementary firing and
[Link] firing of GT
Gas Turbine Steam/Water Injection
Generally steam or water is injected
into the combustor of the GT to control
Nox
Steam or water injection is also done
for increasing power output.
Injection of steam/water increases
the mass flow and, therefore, output.
Supplementary Fired HRSG
The oxygen content available in the
gas turbine exhaust is around 14-15%
This permits supplementary fuel firing
to increase steam production for
increasing steam turbine output
Gas Turbine Peak Firing
Some gas turbine models have the ability to
increase their firing temperature above the base
rating.
This is known as peak firing, where both simple-
cycle and combined-cycle output will increase.
The penalty for this type of operation is shorter
inspection cycles and increased maintenance.
Despite this, running at elevated peak firing
temperatures for short periods may be a cost-
effective way to add kilowatts without the need for
additional peripheral equipment.
THigh firing temperature
leads to better performance.
Typically 55C increase in
firing temperature leads to 8-
13 % increase in output and
2-4 % improvement in heat
rate.
Brayton Cycle
Higher temperature means more output
Higher temperature saves fuel
Higher Firing temperature is beneficial at
higher pressure ratio
Fuel Heating
If low-grade heat energy is available, this can be
used to increase the temperature of gaseous
fuels, which increases cycle efficiency by reducing
the amount of fuel energy used to raise the
fuel temperature to the combustion temperature.
Performance Degradation
All Gas Turbines experiences losses in performance with time
due to very high temperature working zones.
Gas turbine performance degradation can be classified as
recoverable or non-recoverable loss.
Recoverable loss is usually associated with compressor
fouling and can be partially rectified by water washing or,
more thoroughly, by mechanically cleaning the compressor
blades and vanes after opening the unit
Non-recoverable loss is primarily due to increased turbine and
compressor clearances and changes in surface finish and
airfoil contour.
Because this loss is caused by reduction in component
efficiencies, it cannot be recovered by operational procedures,
external maintenance or compressor cleaning, but only
through replacement of affected parts at recommended
inspection intervals.
GT Compressor water wash
Gas turbines use ambient air for the combustion
process.
The solid and condensing particulate matter in the
air, which passes the air inlet, deposit itself on the
surfaces of the compressor blades in course of time,
thus fouling the compressors.
Fouled compressors result in reduced airflow, lower
compressor efficiency and a lower compressor
pressure ratio.
This leads to loss of gas turbine performance
indicated by a decrease in power output and an
increase in heat rate.
Compressor washing removes fouling deposits and
restores performance
GT Compressor water wash-On Line Wash
This is the process of injecting demineralised water
into the compressor while running at full speed,
base load with the intent of removing the deposits
on the compressor blades and thus maintaining
compressor performance.
Online wash frequency can be maintained daily or
weekly depending on the site conditions and
amount of fouling.
The obvious advantage of on-line washing is that it
can be performed while running at load without
shutting down the machine
GT Compressor water wash-Off Line Wash
With regular ON line washing also, it is not possible
to remove certain dirt’s deposited on the
compressor blades and an Off line wash becomes
essential
During the Off-line washing operation, detergent
solution is delivered through piping to the gas
turbine inlet in the proper mix ratio (with water),
pressure, temperature, and flow rate to wash the
gas turbine Compressor, which runs at cranking
speed
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