COMBINED-CYCLE Gas & STEAM TURBINE POWER PLANTS TEST oesaecere sere Second Edition by Rolf Kehlhofer, Rolf Bachmann, Henrik Nielsen, Judy Warner Tulsa, OklahomaCopyright 1999 by PennWell Publishing Company 1421 S, Sheridan Road/P.O. Box 1260 ‘Tulsa, Oklshoma 74101 Library of Congress Cataloging-in-Publication Data Kehlhofer, Rolf Bachmann, Rolf; Nielsen, Henrik; Wamer, Judy Combined Cycle Gas & Steam Turbine Power Plants/Kehihofer, Bachmann, Nielsen, Warner po em, Includes index. ISBN 0-87814-736-5 1 2 L Tite All rights reserved, No part of this book may be reproduced, stored ina retrieval system, or transcribed in any form or by any means, electronic or mechanical including photo- copying or recording, without the prior written permission of the publisher. Printed in the United States of America 345201. % 10. i. 2. 13, Contents List of Figures and Tables Introduction ‘The Electricity Market ‘Thermodynamic Principles of the Combined-Cycle Plant... ‘Combined-Cycle Concepts LAT Applications of Combined-Cycles. 125 Components... 155 ‘Control and Automation 189 ‘Operating and Part Load Behavior ... 1.203 Environmental Considerations... 219 Developmental Trends.. 231 Some Typical Combined-Cycle Plants Conelusion... Appendices.. CONVERSIONS sone Calculation of the Operating Performance of ‘Combined-Cycle Installations Symbols and Indicies Used Bibliography Index ..List of Figures and Tables 24 25 28 27 28 29 240 244 242 214 34 32a Simplified Flow Diagram of a Combined-Cycle Market Development Order Volumes Comparison of Different Turnkey Power Plants in Terms of Specific Price and Output ‘The Cost Percentage of the Different Plant Areas for a Typical 400 MW Turnkey Combined-Cycle Plant Net Efficiencies for GT, CC, ST (Coal Fired), Nuclear and Diesel Power Plants ‘The Cost of Fuels Variable Operating and Maintenance Costs for Various Power Plants of Different Sizes. Fuel costs not included. Fixed Operating and Maintenance Costs for Various Power Plants of Different Sizes. Construction Time for various Power Plants (From ‘Notice To Proceed’ to ‘Commercial Operation’) Dependence of the Cost of Electricity on the Equivalent Utilization Time (100 MW) Dependence of the Cost of Electricity on the Equivalent Utilization Time (400 MW) Dependence of the Cost of Flectricity on the Equivalent Utilization Time (1,000 MW)... Dependence of Cost of Electricity on the Annuity Factor (4,000 hr/annum) Dependence of Cost of Electricity on the Annuity Factor (7,500 hr/annum) Dependence of Cost of Electricity on the Cost of Fuel ‘Temperature/Entropy Diagrams for Various Cycles ‘The Efficiency of a Simple Cycle Gas Turbine with Single Stage Combustion as a Function of Turbine Inlet ‘Temperature (TIT) & the Turbine Exhaust Temperature. 10 15 16 oo8 21 22 23 26 27 29 30 31 32 42.3-2b 33a 3:3b a 42 43 45 46 a7 48 49 Figures and Tables vit 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 ‘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. 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 Energy/Temperature Diagram for an Idealized Heat Exchanger Flow Diagram of a Single Pressure Cycle. Energy/Temperature Diagram for a Single Pressure HRSG Heat Balance for a Single Pressure Cycle. Energy Flow Diagram for the Single Pressure Combined-Cycle Plant Effect of Live Steam Pressure on Steam Turbine Output, Steam Turbine Exhaust Moisture Content and HRSG Efficiency for a Single Pressure Cycle Energy/Temperature Diagram of a Single Pressure HRSG with Live Steam Pressures of 40 and 105 bar Effect of Live Steam Pressure on Condenser Waste Heat at Constant Vacuum Effect of Live Steam Temperature on Steam Turbine ‘Output, HRSG Efficiency and Steam Turbine Exhaust Moisture Content for a Single Pressure Cycle at 105 bar Live Steam Pressure. . Effect of Pinch Point on Relative Steam Turbine ‘Output and Relative HRSG Heating Surface Influence of HRSG Back Pressure on Combined-Cycle Output and Efficiency, GT Output and Efficiency and HRSG Surface 43 AA 45, 49 51 52 53 55 56 37 58 59 61vill Figures and Tables a2 413 414 415 46 a7 418 419 4-20 421 4-22 4-23 4-24 425 426 Effect of Feedwater Temperature on Steam Turbine Output and HRSG Efficiency for aoe with One Stage of Preheating Energy/Temperature Diagram for a Single Pressure HRSG Energy/Temperature Diagram for a Conventional Steam Generator. Flow Diagram of a Single Pressure Cycle with LP Preheating Loop for High-Sulphur Fields Effect of Live Steam Pressure and Feedwater ‘Temperature on Available Heat Compared to Required Heat in Preheating Loop Heat Balance for a Single Pressure Cycle with LP Preheating Loop Energy/Temperature Diagram for a Single Pressure HRSG with LP Evaporator Preheating Loop ... Flow Diagram of a Dual Pressure Cycle for High Sulfur Fuels Effect of Feedwater Temperature and Number of Preheating Stages on Steam Turbine Output of a Dual Pressure Cycle Flow Diagram of a Dual Pressure Cycle for Low Sulfur Fuels Heat Balance for a Dual Pressure Cycle with Low Sulfur Fuel. Energy Flow Diagram for the Dual Pressure Combined-Cycle Plant Energy/Temperature Diagram for a Dual Pressure HRSG Effect of HP and LP Pressure on Steam Turbine ‘Output and Exhaust Moisture Content for a Dual Pressure Cycle Effect of LP Pressure on HRSG Efficiency for a Dual Pressure Cycle 62 63 64 66 or 68. 7 72 73 74 7 78 79427 4-28 4-29 4-30 431 4-32 4.33 4-35 4-36 4.37 4-38 439 4-40 444 4-42 Figures and Tables Effect of LP and HP Steam Temperatures on Steam Turbine Output for a Dual Pressure Cycle Effect of HP and LP Evaporator Pinch Point on Steam Turbine Output and Relative HRSG Surface for a Dual Pressure Cycle Flow Diagram of a Triple Pressure Cycle: Heat Balance for a Triple Pressure CyCle o.oo Energy/Temperature Diagram for a Triple Pressure HRSG . . Energy Flow Diagram for the Triple Pressure Combined-Cycle Plant Steam Turbine Output and Exhaust Moisture Content versus HP and IP Pressure for Triple Pressure Cycle at Constant LP Pressure (5 bar) Effect of LP Pressure on Steam Turbine Output and Relative HRSG Surface for Triple Pressure Cycle at Constant HP (105 bar) and IP (25 bar) Live Steam Temperature Optimization for a Triple Pressure Cycle ‘Temperature/Entropy Diagram Showing the Effect of "Mild Reheat" on the Steam Turbine Expansion Line Effect of HP and IP Evaporator Pinch Points on Steam Turbine Output and Relative HRSG Surface for a Triple Pressure Cycle with Constant LP Pinch Point Flow Diagram of a Triple Pressure Reheat Cycle Heat Balance for a Triple Pressure Reheat Cycle. ‘Temperature/Entropy Diagram Showing the Effect of Full Reheat on the Steam Turbine Expansion Line Energy Flow Diagram for the Triple Pressure Reheat ‘Combined-Cycle Plant . Energy/Temperature Diagram for a Triple Pressure Reheat HRSG sasscssnnns . ix 80 81 82 83 84 85 89 90 a1 92 93 93 94x Figures and Tables 4-43 4.45 4-46 4-48 4-49 4-50 4-52 453 454 4-55 Steam Turbine Output and HRSG Surface versus HP and Reheat Pressure for a Triple Pressure Reheat Cycle at Constant HP (568°C) and Reheat (568°C) Temperature Steam Turbine Output versus HP Steam and Reheat ‘Temperature for a Triple Pressure Reheat Cycle at Constant HP (120 bar), IP (30 bar) and LP (5 bar) Pressure, Flow Diagram of a High Pressure Reheat Cycle with an HP Once Through HRSG and a Drum Type LP Section oe Heat Balance for a Dual Pressure Reheat Cycle with a Once Through HRSG Energy/Temperature Diagram for 647#C(A), 750°C(B) and 1000C(C) Exhaust Gas Temperature Entering the HRSG. - . Effect of Temperature after Supplementary Firing on Power Output and Efficiency Relative to that of a Single Pressure Cycle Heat Balance for a Single Pressure Cycle with Supplementary Firing Selection of a Combined-Cycle Concept, Entropy/Temperature Diagram for a Gas Turbine Process at Two Different Ambient Air Temperatures Relative Efficiency of Gas Turbine, Steam Process and Combined-Cycle as a Function of the Air Temperature at Constant Vacuum Relative Power Output of Gas Turbine, Steam Turbine and Combined-Cycle as a Function of Air Temperature at Constant Vacuum Relative Power Output of Gas Turbine, Steam Turbine and Combined-Cycle and Relative Air Pressure versus Elevation Above Sea Level Relative Power Output and Efficiency of Gas Turbine and Combined-Cycle versus Relative Humidity at Constant Vacuum: 7 100 ol O1 102 105 108 109) 110 an 1124-56 487 4-58 4-59 4-60 4-62 4-63 BA 52 53 55 Figures and Tables 38 Effect of Water and Steam Injection on Relative Combined-Cycle Power Output and Efficiency versus the Water or Steam/Fuel Ratio Effect of Condenser Pressure on Steam Turbine Output ‘Temperature of Cooling Medium versus Condenser Pressure for Direct Cooling, Wet Cooling Tower and Air Cooled Condenser Flow Diagram to Show Fuel Preheating Steam Turbine Output and HRSG Efficiency versus Gas Turbine Exhaust Temperature for a Single Pressure Cycle. Ratio of Steam Turbine Output of a Dual Pressure to that of a Single Pressure Cycle as a Function of Gas Turbine Exhaust Temperature Indicative Relative Price versus Performance of Different Combined-Cycles based on a 178 MW Class Gas Turbine with an Exhaust Gas Temperature Of 647°C LI9TPF) ocnsnnmnntnnnnsnnsnnnnni Indicative Relative Price versus Performance of Different Combined-Cycles based on a 178 MW Class Gas Turbine with an Exhaust Gas Temperature of 525°C (77°F) Simplified Flow Diagram of a Cogeneration Cycle with a Back Pressure Turbine... Flow Diagram of a Cogeneration Cycle with an Extraction/Condensing Steam Turbine Flow Diagram of a Cogeneration Cycle with no Steam Turbine... Heat Balance for a Single Pressure Cogeneration Cycle with Supplementary Firing Effect of Process Steam Pressure on Relative Combined- Cycle Power Output and Power Coefficient for a Single Pressure Cycle with 750°C Supplementary Firing .. 114 7 118 119 121 123 129 130 131 132xii Figures and Tables 56 57 5B 59 510 St 512 513 514 515, 516 S17 518 519 et e2 Effect of Power Coefficient on Blectrical Efficiency and Fuel Utilization for a Single Pressure Cycle with 750°C Supplementary Firing and Decreasing Steam Turbine Back Pressure Flow Diagram of a Cogeneration Cycle with a Dual Pressure HRSG Comparison of 1-Stage and 3-Stage Heating of District Heating Water Heat Balance for a Cycle with Two Stages of District Heating, Flow Diagram of a District Heating/Condensing Cycle. Flow Diagram of a Cycle Coupled with a Seawater Desalination Plant. Flow Diagram of a Conventional Non-reheat Steam Power Plant Flow Diagram of a Combined-Cycle Plant Using an Existing Steam Turbine Flow Diagram of a Gas Turbine Combined with ‘a Conventional Cycle (Hot Wind Box) Flow Diagram of an HEC&G Cycle, Hybrid Power Plant... - . Flow Diagram of a Simplified PFBC Process Flow Diagram of a STIG Cycle Flow Diagram of a Turbo-STIG Cyele. Flow Diagram of a HAT Cycle. Historical Trends in Gas Turbine Inlet ‘Temperatures and Compressor Air Flows Industrial Trent Derived from the Aero Trent 800 Heavy Duty Industrial Gas Turbine Gas Turbine with Sequential Combustion Forced Circulation Heat Recovery Steam Generator Natural Circulation Heat Recovery Steam Generator 146 149) 151 152 153 157 159 160 161 166 1676-10 611 e12 e13 614 72 73 74 76 cae at a2 83 Figures and Tables >it Once-Through HRSG with a Drum Type LP Section Supplementary Fired Heat Recovery Steam Generator Cross Section of a 140 MW Reheat Steam Turbine with a Separate HP Turbine and a Combined IP/LP ‘Turbine with Axial Exhaust . Cross Section of a Two Casing Steam Turbine with Geared HP Turbine Cut-away Drawing of an Air Cooled Generator for use in Combined-Cycle Power Plant. Single Line Diagram ossnitnveen Hierarchic Levels of Automation Standard Layout for a Modern Combined-Cycle Power Plant Control Room . Principle Diagram for a Combined-Cycle Load Control System nnn ‘Typical Combined Cycle Droop Characteristic. Closed Control Loops in a Combined-Cycle Plant Start-up Curve for a 250 MW Class Combined- Cycle after 8 h Standstill Start-up Curve for a 250 MW Class Combined- Cycle after 60 h Standstill Start-up Curve for a 250 MW Class Combined- Cycle after 120 h Standstill.. Combined-Cycle Shut Down Curve... Effect of Vacuum on Combined-Cycle Efficiency. Effect of Frequency on Relative Combined-Cycle Output and Efficiency for Continuous Full Load Operation Part Load Efficiency of Gas Turbine and Combined-Cycle .. 169 174 180 92 2193 195, 201 201 202 202 1.208 209 2uLxiv Figures and Tables a4 85 a6 ot o2 93 25 10-4 10-2 10:3 Wt 11-2 11-3 11-4 115 11-6 17 11-8 Ratio of Steam Turbine and Gas Turbine Output and Live Steam Data of a Combined-Cycle at Part Load Flow Diagram of a Dual Pressure Cycle with Gas Turbine Inlet Air Preheating. Part Load Efficiency of Combined-Cycle Plant with Four Single Shaft Blocks . NO, Equilibrium as a Function of Air Temperature. Flame Temperature as a Function of the Fuel to Air Ratio and Combustion Air Conditions NO, Concentration as a Function of Fuel to Air Ratio and Combustion Air Conditions NO, Reduction Factor as a Function of the ‘Water or Steam to Fuel Ratio in Gas Turbines with Diffusion Combustion Heat Recovery Steam Generator with Selective Catalytic Reduction. Geared High Pressure Turbine Cross Section of a Low NO, Burner Cross Section of a Gas Turbine Combustion Chamber ‘View of Lumut Combined-Cycle Power Plant .. Process Diagram of Lumut Combined-Cycle Power Plant General Arrangement of the Lumut Combined-Cycle Power Plant View of Diemen Combined-Cycle Cogeneration Plant Process Diagram of Diemen Combined-Cycle Cogeneration Plant General Arrangement of Diemen Combined-Cycle Cogeneration Plant King’s Lynn Power Station GUD 18.94.3 (status 9/96) Simplified Diagram of the Single-shaft GUD 18.94.3 Block with a Triple-pressure Reheat Steam Cycle and Air-cooled Condenser 212 213 215 221 222 223 243 245 247 249 251Figures and Tables xv 11-9 Arrangement of the Single-shaft GUD 15.94.3 Block with Air-cooled Condenser (plan view). 253 11-10 View of Taranaki Combined-Cycle Plant 253 11-11 Process Diagram of Taranaki Combined-Cycle Power Plant. 255 11-12 Arrangement of Taranaki Combined-Cycle Power Plant. 255, 11-13 View of IP-Cogen Combined-Cycle ‘Cogeneration Plant 257 11-14 Flow Diagram of IP-Cogen Combined-Cycle Cogeneration Plant 258 11-15 General Arrangement of IP-Cogen Combined-Cycle Cogeneration Plant 260 414-16 Process Diagram for Monterrey Combined-Cycle Power Plant. 262 11-17. Layout of the Monterrey Plant Combined-Cycle Power Plant. 264 A-1 Calculation of Operating and Part-Load Behavior: Method for Solving the System of Equations. 279. Tables 21 World Installed Capacity by Technology and Fuel 8 2-2 World Power Generation by Technology 9 2-3 World Fuel Consumption for Fossil Fueled Power Plants ..10 24 Fuel Flexibility of Various Power Plants 19 25 — Availability and Reliability of Generating Plants 24 31 — Thermodynamic Comparison of Gas Turbine, Steam Turbine and Combined-Cycle Processes 37 32 Allowable Reduction in Steam Process Efficiency as a Function of Gas Turbine Efficiency AL 41 Performance Comparison for Different Cycle Concepts (Natural Gas Fuel with Low Sulfur Content) ....103,xvi Figures and Tables 42 et 62 TA ot 12 113 11-4 15 Possible Fuels for Combined-Cycle Applications... Conversion of a 500-MW Steam Turbine Power Plant into an HEC&G: Performance Data for Different Operating Modes .. Main Characteristics of Modem Gas Turbines for Power Generation. Change of Boundary Conditions for Steam Turbines in Combined-Cycle Plants Operation of Steam Turbine Control Loops in a Combined-Cycle Plant Output and Efficiency of a Combined-Cycle Plant with Cold Water or Steam Injection Compared to the Same Plant without Injection ‘Comparison of the Heat to be Dissipated for different Types of 1000 MW Stations Main Technical Data of the Lumut Combined-Cycle Power Plant. oss Overall Project Development of the Lumut Combined-Cycle Power Plant Main Technical Data of the Diemen Combined-Cycle Cogeneration Plant Main Technical Data of the King's Lynn ‘Combined-Cycle Power Plant Main Technical Data of the Taranaki Combined-Cycle Power Plant Main Technical Data of the IP-Cogen Combined-Cycle Cogeneration Plant Main Technical Data of the Monterrey Combined-Cycle Power Plant 18 147 161 177 197 225 29 244 246 248, 252 254 263up 18009 puv ajo unparsjrorea atp 204 wears joLONIPpE ayeIaUas Tey ‘12009 s18 @ujooo ypias paddmbo st ourgam se8 ou, Y2suapu0d p2qooo yoyo pos urgany UIvaNS w Pure AAI LL Te pares ‘aUgiM SeB uoRSNqUIOD -uo9 $3499 Aupruunyy aan aX qu6S) ‘DoS AmNUsOdUA WaIqUE) SuOREpUOS QS] YO paseg “UAAIE st ‘sadaatoo 9f949 ureur oup Jo Yora JJ aounpeg way Y 'se[OK9 xojduoo axoU ‘oy Bumpeaj pue ajduats wow ain ypym Sunes ‘paureydxo pu paauasaxd ‘am sidaou09 pauiguios uourWos you! ay ‘uoRSeS SYP UT sidaouo9 apAp-pauiquiog sIseg soflunyowg wor pazifeap] ue soy wee aummesaduray ALOU py @unBL sjsu 00g _ — sumenodway, ALNVASNOO = 1 6% sxdooung apo-patuiqwo ‘ape aq seme snr 1809 pue oouruoprod usomieq astuordwos & “sonoesd uy “1809 ayy Surseasou ose mq soueunoprad axp Burvoudwat 9q Ayperaus8 um way atp foo xajduroo asow & Uy a ered ure 917, to pure 1daau0s ayy uo spuadap ( 1eay ou pa) pazuurutur ag uo Sasso] asarp YOM 01 Warxe ay, payo0o aq wea sem IsMey -xa at Yorym oF ammmesaduiay ayn Sun Aq uoHEZETHIN ABI -o 2p SIU STH, ‘SOqM PIOd axp YpEAL ORIUOD OWU SaUIOD 1 axaqps ses ysneyxo auf Uy ZU] spae aatsoxs09 wanard ‘01 yBnoua ysry aq isnt sorempaay ayn yo ammezaduia aT, + rey Ktanuggut 9q rouuea aorpINs sojstEN Vey UL + sassoy oniofzoua pue onafiraxa Sursmeo yoqett 10U Op Sask 1smeya pur wivars ‘rayeas atp Jo saniadosd yworssyd ou, 10) -oj ureUn damp TEN Pareroosse Sasso] s|reIU OSYH Ue UT TaysuEN 1woHy ay, “O19 spreMoy Sasso] ABIoxa yp pure ANTULJUT SpUMO) spual 2aBuEYD -x9 Way a1p Jo spavanor sputar aouasaystp aimeraduiay siqy sy “wIpaur oa op waartaq souasayP ammoduioy ve 9q rsh arom aaeyd ayer 01 zaysuen ABsoUa OF s0pI0 UY “S9sS0] ABO xo pie Br0U9 Iwaxaud o1 tHOd waa! 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