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Handbook For Cogeneration and Combined Cycle Power Plants
Handbook For Cogeneration and Combined Cycle Power Plants
FOR COGENERATION
AND COMBINED
CYCLE POWER PLANTS
Second Edition
TABLE OF CONTENTS
DEDICATION
PREFACE
iii
xv
1
17
21
21
21
22
23
27
27
27
29
34
35
39
44
46
47
47
50
50
50
53
53
54
57
59
TABLE OF CONTENTS ix
6. AN OVERVIEW OF PUMPS
297
2. CYCLES
61
117
119
119
122
122
128
128
129
130
130
131
131
131
132
132
133
134
134
135
135
135
136
136
138
138
138
139
139
139
140
140
140
140
140
141
141
141
146
148
149
151
155
239
Introduction................................................................................................. 239
Non-Condensing Cycle............................................................................ 239
Condensing Cycle.................................................................................... 239
The Rankine Cycle........................................................................................ 240
Heat Rate and Steam Rate.....................................................................243
Turbine Component Efficiency..............................................................243
Mechanical Efficiency.............................................................................244
The Regenerative - Reheat Cycle...........................................................244
Steam Turbine.........................................................................................246
Classifications of Steam Turbines........................................................... 247
Steam Flow Directions............................................................................ 247
Steam Passage Between Blades............................................................. 249
Turbine Stages in Series.......................................................................... 249
Single-Stage or Simple-Impulse Turbine............................................... 250
Multistage Impulse-Type Turbine.......................................................... 251
Velocity and Pressure Stage Combination............................................ 251
TABLE OF CONTENTS ix
6. AN OVERVIEW OF PUMPS
297
317
Introduction ................................................................................................317
Design Considerations . ..............................................................................320
Multipressure Steam Generators ..........................................................320
Off-Design Performance .......................................................................322
Construction of the HRSG .....................................................................323
Casing of the HRSG . ..............................................................................324
Forced-Circulation System .....................................................................324
Back-Pressure Considerations (Gas Side) ..............................................324
Finned Tubing ........................................................................................324
Tube Materials .......................................................................................324
HRSG Design Requirements ..................................................................325
Economizers ...........................................................................................326
Evaporators ............................................................................................327
Attemperators .......................................................................................329
Desuperheaters ......................................................................................330
Deaerator ....................................................................................................333
Supplementary Firing of Heat Recovery Systems . ...............................335
Design Features .....................................................................................338
Once Through Steam Generators .........................................................342
HRSG Operational Characteristics . .......................................................344
HRSG Effectiveness ................................................................................346
Water Chemistry ....................................................................................346
Water Treatment Plants ........................................................................348
Chemical Storage and Dosing ...............................................................352
HRSG Chemical Cleaning .......................................................................352
Vibration and Noise . .............................................................................356
Filter Housing, Duct Work, and Insulation . .........................................357
Diverters, Silencers, and Burners ..........................................................360
HRSG Reliability and Durability ............................................................365
367
TABLE OF CONTENTS xi
Motors ........................................................................................................
Constant Speed Motors ........................................................................
Alternating Current Squirrel-Cage Induction Motors ......................
Synchronous Alternating-Current Motors ..........................................
Power-Factor Correction ......................................................................
Generator . ...............................................................................................
Design Characteristics . ........................................................................
Switchgear ...............................................................................................
Electrical Single Line Diagram ..................................................................
371
376
381
383
385
389
390
390
391
391
392
395
395
396
396
397
398
399
402
417
423
425
427
430
442
446
446
448
449
450
452
458
459
459
460
460
460
461
461
461
464
HANDBOOK
FOR COGENERATION
AND COMBINED
CYCLE POWER PLANTS
Second Edition
546
546
548
549
554
564
567
571
572
575
575
577
580
580
580
583
588
589
589
590
598
599
603
603
606
607
607
611
611
611
615
615
615
616
631
634
637
641
648
650
653
662
671
672
676
677
680
689
690
691
692
694
699
702
706
708
709
715
722
APPENDIX A
725
APPENDIX B
729
BIBLIOGRAPHY
731
INDEX
747
761
PREFACE
A Handbook for Cogeneration and Combined Cycle Power Plants discusses the
design, fabrication, installation, operation, and maintenance of combined cycle
power plants. The book has been written to provide an overall view for the
experienced engineer working in a specialized aspect of the subject and for the
young engineering graduate or undergraduate student who is being exposed to
the field of power plants for the first time. The book has proven to be very useful
as a textbook for undergraduate and graduate courses as well as for in-house
company training programs related to power generation, and I believe that the
new edition will further extend the knowledge of the engineer in this field.
The second edition is not only an updating of the technology, which has taken
great leaps forward since the year 2001, but I have also rewritten the introductory
chapter to bring the reader new information in the power industry, especially
carbon sequestration technology, which will be a topic of great interest in the
years to come. The power industry has, in the past 8 years, embraced the combined
cycle power plants and, with the new high-efficiency advanced gas turbines, is at
the center of this growth segment of the industry. This has led to the rewriting of
the following chapters: Chapter 1, An Overview of Power Generation; Chapter
5, Steam Turbines; Chapter 7, Heat Recovery Steam Generators; and Chapter
8, Condensers and Cooling Towers.
A new chapter has been introduced, Chapter 15, Case Histories of Problems
Encountered in Cogeneration and Combined Cycle Power Plants. This is an
extensive treatise on the many problems associated with the combined cycle
power plants and some of the solutions that have achieved higher efficiencies
and reliability. This chapter explains in depth the problems encountered and with
145 figures fully illustrates the many failures encountered in cogeneration and
combined cycle power plant applications.
This book has been used extensively by engineers in the industry, and I have
used it in the many courses I have taught in this area. The suggestions from these
engineers have guided me in my writing of the second edition of this book. The
new chapters have been written with an eye toward the new issues both from a
technical and legal point of view in the operating of power plants. In this new
edition, I have introduced extensive sections on the chemical treatment of the
water used in combined cycle power plants. The chemistry sections and related
information have been provided by David Addison of Thermal Chemistry Limited,
New Zealand. I have also used many topics that have been well researched by the
Electric Power Research Institute in its many publications.
Cogeneration and combined cycle power plants are not new, but with major
improvements in all of the building blocks such as power plant, gas turbines,
HRSGs, steam turbines, and condensers, an update of the book was necessary.
Technology efficiencies in the mid-1950s are common today, and with a little bit
of ingenuity, efficiencies in the low 1960s will be possible. With emphasis on CO2
reduction, these high efficiencies will make it possible to achieve the lofty goals
of greenhouse gas reductions. These high efficiencies have totally revolutionized
the industry, making the old steam plants a thing of the past.
The use of cogeneration and combined cycle power plants in all industries,
and in the power generation field, has mushroomed in the past few years. It is to
these users and manufacturers of cogeneration and combined cycle power plants
that this book is directed. The book, with its new chapter on case histories, will
give the manufacturer a glimpse of some of the major problems associated with
his equipment in the field and help the user to achieve maximum performance
efficiency and high availability for his plant.
I have been involved in the research, design, operation, and maintenance
of various types of combined cycle power plants since the early 1960s. I have
also taught courses at the graduate and undergraduate level at the University
of Oklahoma and Texas A&M University, and now, in general, to the industry
for the past 30 years. I have taught over a hundred courses to 3000 students
from over 400 corporations around the world. The enthusiasm of the students
associated with these courses gave me the inspiration to undertake this endeavor
of updating the book. The many courses I have taught over the past 37 years
have been an educational experience for me as well as for the engineers who
have participated in these courses. The Texas A&M University Turbomachinery
Symposium, which I had the privilege to found and chair for seven years and
which is now in its 38th year, is a great contributor to the operational and
maintenance sections of this book. The discussions and consultations that
resulted from my association with highly professional individuals have been a
major contribution to both my personal and professional life as well as to this
book.
In this book, I have tried to assimilate the subject matter of various papers,
and sometimes diverse views, into a comprehensive, unified treatment of
combined cycle power plants. Many illustrations, curves, and tables are
employed to broaden the understanding of the descriptive text. Mathematical
treatments have been deliberately held to a minimum so that the reader can
identify and resolve any problems before he is ready to execute a specific design.
In addition, the references direct the reader to sources of information that will
help him to further investigate and solve his specific problems. It is hoped that
this book will serve as a reference text after it has accomplished its primary
objective of introducing the reader to the broad subject of combined cycle power
plants.
I wish to thank the many engineers whose published work and discussions
have been a cornerstone to this work. Lastly, I wish to acknowledge and give
special thanks to my wife, Zarine, for her readiness to help and her constant
encouragement throughout this project. I also would like to thank my assistants
Donna Masters and Shannon Reynolds for the many hours they have spent in
helping me put this new edition together.
PREFACE xvii
I sincerely hope that this new edition will be educational and interesting to
read as it was for me to write and that it will be a major reference in the fastgrowing field of cogeneration and combined cycle power plants.
MEHERWAN P. BOYCE
HOUSTON, TEXAS
September 2009