220365en - Combined Cycle Power Plant Overview

Overview & Introduction Combined Cycle
Power Plant Overview

(Single- and Multi-Shaft)
Training Lesson
ALSTOM (Switzerland) Ltd ABCD

CCPP Overview
ABCD Overview & Introduction (Single- and Multi-Shaft)
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 2005
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.
Power Plant Training Center

CSXA220365en_ Page 2
CCPP Overview
Table of Contents
Document Reference ........................................................................................................................... 4

Typical Documents ........................................................................................................................... 4
O&M Documentation ....................................................................................................................... 4
Lesson Objectives................................................................................................................................ 5
Introduction ........................................................................................................................................ 6
Gas Turbine Power Plant ..................................................................................................................... 7
General........................................................................................................................................... 7
Gas Turbine, Components and Functional Principle ........................................................................... 8
Generator, Components and Functional Principle ............................................................................ 10
Steam Turbine Power Plant ................................................................................................................ 12
General......................................................................................................................................... 12
Steam Turbine, Components and Functional Principle ...................................................................... 13
Boiler, Components and Functional Principle ................................................................................... 14
Water Steam Cycle, Components.................................................................................................... 15
Generator...................................................................................................................................... 17
Combined Cycle Power Plant for Delivery of Electricity......................................................................... 18
Multi-Shaft Arrangement ................................................................................................................ 18
Single-Shaft Arrangement............................................................................................................... 20
Combined Cycle Power Plant for Delivery of Heat and Electricity .......................................................... 22
Multi-Shaft Arrangement ................................................................................................................ 22
Overview of a Combined Cycle Power Plant for CHE Supply................................................................ 26
Single-Shaft Arrangement............................................................................................................... 26
Control and Protection Systems .......................................................................................................... 28
Test Questions for Verification of Learning Progress ......................................................................... 32
Questions: ..................................................................................................................................... 32
Lesson Test Questions Solution Key ................................................................................................. 36
Summary .......................................................................................................................................... 36
Table of Figures
Figure 1: Gas Turbine Power Plant with Static Excitation, its Major Components and Controls (Typical) ... 7
Figure 2: Steam Turbine Power Plant with Static Excitation, its Major Components and Controls ...............
(Typical) ............................................................................................................................ 12
Figure 3: Flow Diagram of a Single Pressure Cycle (Typical) ............................................................... 15
Figure 4.1: Combined Cycle Power Plant Process Overview (Multi-Shaft) (Typical)................................ 18
Figure 4.2: Combined Cycle Power Plant Process Overview (Single-Shaft) (Typical) .............................. 20
Figure 5.1: Combined Cycle Plant for CHE Supply and Multi-Shaft Arrangement (Typical).................... 22
Figure 5.2: CHE Supply Plant (Typical)............................................................................................... 24
Figure 5.3: Combined Cycle Plant for CHE Supply and Single-Shaft Arrangement (Typical) .................. 26
Figure 6: Basic Scheme of the Control of a Combined Cycle Power Plant (Typical) ............................... 28

CCPP Overview
Document Reference
Typical Documents
Typical documents are used to clarify aspects described in this lesson. These typical
documents may not show project specific contents, deviations are possible. All
typical documents are clearly identified.
O&M Documentation
O&M (Operation & Maintenance) Documents are plant specific and form an
important part of each training course. A selection of the most relevant O&M
Documents has been made and included in the training course material. These
documents provide a basis for exercises and personal notes, markings, etc. The
most relevant documents for the training are:
• P&IDs (Process & Instrumentation Diagram) with legend
• Combined cycle operating concept
• System description
• Maintenance manual
The O&M Documents are separated into:

• System specific documents
• Overall plant specific documents
The system specific documents are in principle not attached to each specific lesson,
whereas the overall plant specific documents can be found in separate sections at
the end of the training manual.

CCPP Overview
Lesson Objectives
Upon completion of this lesson, the trainee is able to:
• Give reasons why combined cycle power plants are used for supplying electric
energy.
• Explain why a gas turbine set includes:
• A turbine
• A combustion chamber
• A compressor
• List the energy conversions in a combined cycle power plant.

• Give the reasons why the main electrical energy supply chain contains:
• A generator
• An exciter
• Generator bushings
• A generator breaker
• A main step-up transformer
• A grid breaker
• Explain the purpose of the economizer, evaporator and superheater in the heat
recovery steam generator (HRSG).
• List the components between gas turbine generator and the high voltage power
line.
• List the components between steam turbine generator and the high voltage
power line.
• Explain the purpose of the following components
• Heat recovery steam generator
• Condenser
• Deaerator
• Feed water storage tank
• Justify the use of a combined cycle plant as a process for combined heat and
electricity supply.
• State the reasons of the following control components in a combined cycle
power plant:
• Electronic gas turbine controller (EGATROL)
• Steam turbine closed loop controller (TURBOTROL)
• Steam turbine sequencer (TURBOMAT)
• Excitation control
• Synchronizing control
• Generator protection
• Heat recovery steam generator control

CCPP Overview
Introduction
CCPP for highest In the field of thermoelectric power plants the utmost energy utilization is achieved
Efficiency by the combination of a gas turbine and a steam turbine power plant. The two
plants are linked together by a heat recovery steam generator (HRSG).
This type of a thermoelectric power plant is called combined cycle power plant
(CCPP).
Consequently, CCPPs take the advantages of gas turbines and steam turbines and
combine them in an arrangement that provides electric power at a much higher
efficiency than is possible with either system operating alone.
This section will briefly describe the process of typical ALSTOM gas and steam
turbine power plants but also how those processes are combined in a typical CCPP.
The material does not describe all equipment, but rather focuses on major
components, which are essential to an understanding of the overall process.

CCPP Overview
Gas Turbine Power Plant

General
SETPOINTS
Load (Speed)
Electronic gas turbine

controller (EGATROL *)
- Sequencing Synchronizing
- Control (open/closed loop) control
- Protection
- Limiter
Generator
protection
Excitation control,
Automatic voltage
regulator (AVR)
Ambient
Fuel control air
valve
Fuel supply
DC Generator breaker
Temp. after Turbine inlet Air flow Generator
turbine (TAT) temp. (TIT) by vanes Neutral point terminals
position DC Static starting
device (SSD)
HV breaker
Magnetic field
Exhaust gas Unit auxiliary

Generator Brushes for transformer
- exitation Generator step-up
- start-up transformer
* Trade Name ALSTOM Self consumption CSXA403476.cdr
Figure 1: Gas Turbine Power Plant with Static Excitation, its Major Components and Controls (Typical)
(Continued next page)

CCPP Overview
General (continued)
Gas Turbine ALSTOM produces a variety of gas turbine types, which differ in:
• Configuration
• Electric power output
However, the energy conversion process from

• chemical energy to
• thermal energy to
• mechanical energy and then to
• electrical energy
is similar in all type of gas turbine plants.
Gas Turbine The supply of electric energy from a gas turbine power plant requires the use of:
operated Power • A gas turbine
Plants
• A generator
• An excitation system
• Generator bushings (terminals)
• A generator breaker
• A generator step-up transformer
• A grid breaker (HV breaker)
The role of each will be briefly described.
Gas Turbine, Components and Functional Principle
Gas Turbine The gas turbine is composed of three processing elements:

• An air compressor
• A combustion chamber with burner (s)
• The turbine

CCPP Overview
Gas Turbine, Components and Functional Principle (continued)
Compressor The pressurized air entering the combustion chamber is delivered by the axial
compressor. The latter:
• Transfers kinetic energy provided from the compressor blading to the flowing
air so the pressure of the air is increased.
(Kinetic energy is transferred to pressure energy)
• The air within the compressor is pressurized with the help of rotating and
stationary blading
• Is driven by the turbine through the common shaft.
A portion of the pressurized air is also used for sealing and cooling of the gas
turbine.
Combustion The combustion gas that drives the turbine is supplied via an enclosed, pressurized
Chamber fired room, called the combustion chamber.
In the combustion chamber
• Liquid or gaseous fuel is continuously burned. The required oxygen for the firing
process is taken from the compressor air. By the firing the temperature of the
compressor discharge air is increased, the pressure in the combustion chamber
does not increase however. With other words:
• The chemical energy of the fuel is converted into thermal energy.
Turbine The turbine

• Converts the thermal energy of the combustion fuel into mechanical energy.
• Is the prime mover that drives the axial compressor and the generator.
Is driven by the compressed and heated combustion gas that strikes blading
mounted on the rotor, and causes it to turn.
Air Flow Control The air flow and consequently the combustion gas flow through the turbine is
controlled by the appropriate setting of the position of the variable guide vanes
mounted before the compressor inlet. They can assume, hold and change to any air
mass flow between a minimum (approx. 60% of the maximum) and the maximum
of air flow.
Fuel Control The fuel throughput to the combustion chamber is controlled by the appropriate
setting of control valve(s), which can assume, hold and change to any position
between fully closed and fully open.

CCPP Overview
Generator, Components and Functional Principle
Generator The generator:

• Is the machine driven from the gas turbine.
• Converts the mechanical energy of the turbine into electrical energy.
• Is composed of
• A non-movable part called the stator
• a movable part called the rotor.
The generator rotor is coupled to the turbine rotor, either

• directly or
• through a speed reduction gear.
Rotor, Magnetic The rotor creates the rotating magnetic field inside the generator by the
Field combination of the steel sheet package and the excitation or field winding, in which
a direct current (DC) flows.
The excitation field winding is often referred to simply as the rotor winding.
The strength of the magnetic field must be adjusted to correspond to the electrical
power output of the generator. The consequences of this measures are:
• The generator is kept in synchronism with the HV power line.
• The generator voltage, the active and the reactive power supplied to the HV
power line are kept within specified limits.
This is accomplished by means of a direct current:
• Referred to as an excitation current.
• Passed through the rotor field winding.
The automatic voltage regulator (AVR) equipment controls the excitation current in
turn. The latter controls both:
• The terminal voltage of the generator.
• The active and reactive electric power supply to the HV power line.
The stator contains fixed windings inside which an alternating voltage is induced by
the rotating magnetic field.
Excitation The excitation system provides the direct current for the windings of the generators
rotating magnetic field.
• Two types of excitation systems are in use:
• Brushless, i.e. an exciter machine coupled to the generator
• Static that means outside the generator alternating current is rectified. The
direct current is supplied to the rotor excitation winding via two brushes
Both systems perform the same function.

CCPP Overview
Generator, Components and Functional Principle (continued)
Generator The generators bushings also called generator terminals.

Breaker • Provide the connection that enables the electric energy of the generator to be
delivered to the outside HV power line.
• Are mounted on the generator stator housing.
• Receive the output voltage of the stator windings.
Main Step-up The generator breaker enables the electrical connection between the generators
Transformer bushings and the step-up transformer.
During the standstill and start up operation of the gas turbine the generator breaker
isolates the generator from the HV power line.
The main step-up transformer:

• Is used to match the terminal voltage of the generator to the voltage of the HV
power line or network.
• Also works like an electric buffer in case of short circuit in the HV power line,
protecting the generator.
The grid breaker (HV breaker):

• Provides the electrical connection between the substation and the HV power line
or network.
• Disconnects the gasturboset from the HV power line in case of network failures,
allowing it to run on island duty.
• Is an optional piece of equipment.

CCPP Overview
Steam Turbine Power Plant

General
SETPOINTS
Load (Speed)
Steam turbine closed

loop controller Synchronizing
(TURBOTROL *) control
Steam turbine
sequencer (TURBOMAT *)
- Control
- Regulation
- Protection
Generator
protection
Excitation control,
Automatic voltage
regulator (AVR)
Possibly steam
extraction:
- industrial application To
atmosphere Trip and control
- de-salination
valves
- district heating etc
Generator
Neutral point terminals
HRSG DC
(boiler)
HV
Steam turbine Magnetic field breaker
Possibly: Steam
by-pass Pressurized
stack Generator Brushes for exitation
water Generator step-up
transformer
Steam turbine
bypass line
Make-up Cooling medium
Exhaust gas from GT water
(in special cases with
additional firing) Deaerator and Condenser and
feed water hot well
storage tank
Boiler feed water pump Condensate pump * Trade names ALSTOM CSXA403477.cdr
Figure 2: Steam Turbine Power Plant with Static Excitation, its Major Components and Controls (Typical)

CCPP Overview
Steam Turbine, Components and Functional Principle
ALSTOM produces a variety of steam turbine power plants, which differ in:
• Configuration
• Electric power output
Components The supply of electric energy from a steam turbine power plant requires the use of:
• A boiler
• A steam turbine
• The boiler and the steam turbine are linked together by the water steam cycle
(WSC)
• A generator
• An excitation system
• A generator bushings
• A circuit breaker
• A step-up transformer
The role of each will be briefly described.
Steam Turbine Steam lines forward the steam raised in the HRSG to the steam turbine.
• The steam massflow, which passes through the turbine, is regulated by the
opening stroke of control valves.
• As steam flows through the turbine it strikes the blades on the rotor, resulting in
a force. The tangential force causes the rotor to turn.
• This is an energy conversion process from thermal energy to mechanical
energy.

CCPP Overview
Boiler, Components and Functional Principle
The boiler in a CCPP is called heat recovery steam generator (HRSG).

• It is the place where the energy transfer from the exhaust gas to the water and
steam cycle takes place. The cooled exhaust gas leaves the HRSG via the stack.
• Feed water pumps increase the water pressure before it enters the HRSG. In the
boiler – by heat transfer - the water temperature is increased and starts boiling.
With continued heat transfer the steam is superheated. Thereafter the steam is
conducted to the steam turbine.
If not provided with an additional fuel firing, no energy conversion results in the
HRSG. Only an energy transfer and subsequent change of
• the water to boiling state and then
• to steam and then
• to superheated steam
takes place however.
To secure the integrity of the boiler, it must be fed continuously with water.
Boiler Sections A simple boiler includes a:

• First heat exchanger called economizer.
• Second heat exchanger called evaporator, normally in combination with a water
and steam filled drum.
• Third heat exchanger called superheater.

CCPP Overview
Water Steam Cycle, Components
12
15
13
5
14
7
Natural Gas
2
8 G
9
G 1 3
1 Air compressor 10
2 Combustion chamber 7 Drum 12 Feedwater tank/dearator
3 Turbine (gas) 8 Steam turbine 13 Feedwater pump
4 Superheater 9 Steam turbine bypass 14 GT cooling air cooler
5 Evaporator 10 Condenser 15 Pegging steam line 11
6 Economizer 11 Condensate pump G Generator
CSXA403491.cdr
Figure 3: Flow Diagram of a Single Pressure Cycle (Typical)
A simple water steam cycle consists besides the boiler and the steam turbine of a:
• Steam condenser
• Condensate pump
• Feed water tank with deaerator
• Feed water pump
In order to increase the efficiency of a steam turbine plant a pressure well below
ambient pressure (down to an absolute pressure of 0.05 bar) is created at the end
of the steam turbine. This pressure exists in the condenser as well.

CCPP Overview
Water Steam Cycle, Components (continued)
Condenser After leaving the last turbine stage the steam is exhausted. This exhaust steam
enters the condenser and is cooled. Thus the state of steam changes back to water
(condensate). The condensate is collected in the hot well; this is the lowest section of
the condenser.
The condenser is another heat exchanger. Condensation is by heat transfer from
steam either to
• cooling water,
• cooling seawater, or
• cooling air.
The cooling medium circulates through pipe bunches inside the condenser casing.
The condensation temperature depends on pressure, assuming the steam absolute
pressure is 0.082 bar, then the condensation temperature is 42 °C.
Condensate The condensate pump forwards the water from the hot well of the condensers to the
Pump feed water tank. Special care must be taken, because the water pressure at the inlet
flange of the condensate pump must be higher than the pressure in the condenser.
Feed Water Tank After the condensate pump(s) the water is sprayed via a dome into the feed water
tank. There it is
• deaerated by means of steam
• preheated and
• stored for feeding the HRSG.
For safety reasons the feed water tank is located on top of the boiler.
(Water circulation by gravity in case of a power loss).
De-aeration The condensate enters the feed water tank over a top assembly called dome. There
the condensate is dispersed, water droplets flow down. Bleeding steam from the ST
heats the droplets, its solubility for air and gas decreases. The escaped air rises to
the top of the dome and is sucked off by an under pressure piping and directed to
the main steam condenser.
Feed Water The feed water pump forwards the water – at the required system pressure – from
Pump the feed water tank back to the boiler.

CCPP Overview
Generator
Generator of The conversion from mechanical to electrical energy takes place through the
Steam Turbine generator and exciter in a process, which is essentially the same as that described
above for the gasturboset.
The significant difference to the gas turbine power plant is the synchronization of
the generator to the HV power line. The steam turbine is synchronized – that means
connected to the HV power line – by the HV breaker. A generator breaker is not
installed in the steam turbine plant.

CCPP Overview
Combined Cycle Power Plant for Delivery of Electricity

Multi-Shaft Arrangement
Deaerator
feedwater
storage tank
Heat recovery
steam generator
Low / intermediate Low pressure

Steam pressure
HRSG pressure deaeration steam
reducing valve
feedwater pump High pressure control valve
feedwater pump
Low pressure
Feedwater
economizer
control valve
Low pressure LP steam drum

evaporator
Low pressure water
Intermediate pressure circulation pump
economizer
Intermediate pressure IP steam drum

evaporator
High pressure Intermediate pressure water

economizer circulation pump
Intermediate pressure
superheater
High pressure HP steam drum

evaporator High pressure water
circulation pump
High pressure
superheater and
intermediate pressure
reheater
LP steam
Compressor Generator turbine
Gas
turbine G G
Generator
HP steam
turbine Cooling
IP steam
turbine
Combustion Medium
chamber Main
Natural gas condenser
Condensate
Fuel gas extraction pump
preheater
CSXA400185.cdr
Figure 4.1: Combined Cycle Power Plant Process Overview (Multi-Shaft) (Typical)

CCPP Overview
Multi-Shaft Arrangement (continued)
To fulfil the above objective, the major components of a multi shaft combined cycle
power plant are:
• One or more gas turbines
• One or more heat recovery steam generators (HRSG)
• One steam turbine
• Two or more generators
• A water steam cycle
• Balance of plant equipment
• Control, monitoring and protection equipment
The process starts when the gas turbine is put in operation.

• The gas turbine operates on fuel fired in the combustion chamber, which mixes
with the compressor discharge air.
• The resulting hot combustion gas is expanded when flowing through the
turbine, causing the shaft to rotate.
• The gas turbine rotor is connected to the generator rotor, either directly or via a
speed reduction gear.
• The generator converts the mechanical energy into electrical energy, which is
supplied to the HV power line.
The exhaust gas leaves the turbine portion still at a high temperature.
• If the gas turbine is operated in single cycle, this heat energy is discharged to
atmosphere and thus wasted.
• However, if the gas turbine is operated in combined cycle, the exhaust gas flow
is directed to an HRSG. Here, the thermal energy from the exhaust gas is
transferred to water and steam respectively.
That is, the HRSG links together the gas turbine process and the water steam cycle.
When the steam is at the specified temperature and pressure, it is forwarded to the
steam turbine where it expands through the turbine. Its mechanical power is
transmitted via the shaft to the generator and there converted to electrical power.
Exhausted steam is directed to a condenser, where it is cooled to water called

condensate. The condensate is then directed to the feed water storage tank. Here
the condensate is
• deaerated by means of steam
• preheated and
• stored for feeding the HRSG.
The water is then pressurized by the feed water pump and circulates through the
HRSG again.

CCPP Overview
Single-Shaft Arrangement
Deaerator
feedwater
storage tank
Heat recovery
steam generator
Low / intermediate Low pressure
Steam pressure
HRSG pressure deaeration steam
reducing valve
feedwater pump High pressure control valve
feedwater pump
Low pressure
Feedwater
economizer
control valve
Low pressure LP steam drum

evaporator
Low pressure water
Intermediate pressure circulation pump
economizer
Intermediate pressure IP steam drum

evaporator
Intermediate pressure water
High pressure
circulation pump
economizer
Intermediate pressure
superheater
High pressure HP steam drum

evaporator
High pressure water
circulation pump
High pressure
superheater and
intermediate pressure
reheater
Compressor Generator LP steam

turbine
Gas
turbine G
Self shifting and
synchronicing clutch HP steam
turbine Cooling
IP steam
turbine
Combustion Medium
chamber Main
Natural gas condenser
Condensate
Fuel gas extraction pump
preheater
CSXA400186.cdr
Figure 4.2: Combined Cycle Power Plant Process Overview (Single-Shaft) (Typical)

CCPP Overview
Single-Shaft Arrangement (continued)
To fulfil the objective, the major components of a single shaft combined cycle power
plant are:
• One gas turbine
• One generator
• One self shifting and synchronizing (SSS) clutch
• The water steam cycle, mainly composed of
• A heat recovery steam generator (HRSG)
• A steam condenser
• Condensate extraction pump(s)
• A feed water storage tank with deaerator
• Feed water pump(s)
The single shaft combined cycle power plant functions in the same way as the multi
shaft arrangement.
The most important difference is the application of the SSS clutch, installed between
the generator and the steam turbine. The SSS clutch permits to accelerate the gas
turbine and later the steam turbine each independently from the other. Only when
the steam turbine surpasses the rotational speed of the generator the SSS clutch
engages automatically.
The SSS clutch:

• Engages automatically as soon as the torque from the steam turbine shaft
becomes positive; that is as soon as the rotational speed of the steam turbine
tends to outrange that of the generator.
• Disengages automatically as soon as – after a shutdown – the torque of the
steam turbine shaft becomes negative.

CCPP Overview
Combined Cycle Power Plant for Delivery of Heat and Electricity

Multi-Shaft Arrangement
Flue gases
Natural gas
Air (fuel oil)
inlet
100°C
Heat-
recovery
steam
Electricity
boiler
(HRSB)
500°C
Generator
Gas turbine
Electricity
Steam
Steam
turbine
Generator Heating
condenser
Condenser
Feedwater
Cooling water District heating

system CSXA400187.cdr
Figure 5.1: Combined Cycle Plant for CHE Supply and Multi-Shaft Arrangement (Typical)

CCPP Overview
The objective of a combined cycle power plant for Combined Heat and Electricity
(CHE) supply with multi-shaft arrangement is to deliver simultaneously:
• Steam and
• Electricity
This process is known as CHE supply.
To fulfil the above objective, the major components of a multiple shaft combined
cycle plant for CHE supply are:
• One or more gas turbines
• One or more HRSGs
• Two or more generators
• One condensers
• A water-steam cycle
All the previous descriptions apply to this type of combined cycle plant plus the
following explanations:
• The heat supply happens normally with one of the two heat carriers, that is
steam or water.
• Steam is normally extracted at some stages of the steam turbine. This steam can
then be used directly for heating purposes or can be used indirectly for heating
purposes across a corresponding heat exchanger.
• Depending on heat demand, the supply of this energy form can be completely
suspended. In this case the combined cycle plant runs only delivering electricity.

CCPP Overview
Flue gases
Natural gas
Air (fuel oil)
Deaerator
feedwater inlet
storage tank
Heat
recovery
steam
boiler
(HRSB)
Electricity
Boiler Heat consumer

feedwater pump Generator Gas turbine
SSS: self synchronyzing

and shifting
CHE: combined heat
Circu- Condensate
and electricity
lating extraction
pump pumps CW
circulating
Condensate pump
District heating system Cooling water (CW)
CSXA400189.cdr
Figure 5.2: CHE Supply Plant (Typical)

CCPP Overview
An interesting alternative is the arrangement of a combined cycle power plant for

CHE supply, but without the steam turbine in the water steam cycle.
• The heat from the HRSG is used in this case directly for industrial processes like:
• Petrochemical plants,
• sea water desalination plants,
• district heating, etc.
• Normally in this case, the HRSG is equipped with supplementary inlet duct
burners to secure the heat supply if the gas turbine alternator set is out of duty.

CCPP Overview
Overview of a Combined Cycle Power Plant for CHE Supply

Single-Shaft Arrangement
Flue gases
Natural gas
Air (fuel oil)
Deaerator
feedwater inlet
storage tank
Heat
recovery
steam
boiler
(HRSB)
Electricity
Steam
Steam
turbine
Boiler
feedwater pump SSS clutch Generator Gas turbine
Heating Main
condenser condenser
SSS: self synchronyzing
and shifting
Circu- Condensate
lating extraction
pump pumps
CW
Condensate circulating
pump
District heating system Cooling water (CW)
CSXA400188.cdr
Figure 5.3: Combined Cycle Plant for CHE Supply and Single-Shaft Arrangement (Typical)

CCPP Overview
Single-Shaft Arrangement (continued)
The objective of a combined cycle power plant for CHE supply with single-shaft
arrangement is to deliver simultaneously:
• Steam and
• Electricity
This process is known as CHE supply.
To fulfil the above objective, the major components of a single shaft combined cycle
plant for CHE supply are:
• One gas turbine
• One generator
• One self shifting and synchronizing (SSS) clutch
• The water steam cycle, mainly composed of:
• A heat recovery steam generator (HRSG)
• A steam condenser
• A heating condenser
• Condensate extraction pump(s)
• A feed water storage tank with deaerator
• Feed water pump(s)
All the previous descriptions apply to this type of combined cycle plant plus the
following explanations:
• The heat supply happens normally with one of the two heat carriers, that is
steam or water.
• Steam is normally extracted at some stages of the steam turbine. This steam can
then be used directly for heating purposes or can be used indirectly for heating
purposes across a corresponding heat exchanger.
• Depending on heat demand, the supply of this energy form can be
completely suspended. In this case the combined cycle plant runs only
delivering electricity.

CCPP Overview
Control and Protection Systems
Importance of automated control systems

Today's complex power plants operate at very high efficiency because of the
sophisticated design of the equipment used.
• To reach these high levels of efficiency and reliability, automation systems have
become standard in the industry.
• ALSTOM's major control and protection systems are briefly outlined below
• Details are provided in the respective gas and steam turbine training
modules
AUTOMATIC GENERATION
HMI
CONTROL
GT CONTROL HRSG CONTROLLER

BOP ST SEQUENCER MISCELANEOUS
HMI (open-and closed- (open-and closed-
CONTROLLER (open-loop control) (water steam cycle)
loop control) loop control)
ST CLOSED
LOOP
CONTROLLER
(closed-loop
control)
BOP equipment like: 7 4
-Main cooling water 5

-Main condenser tube 12
10
-cleaning system
-Cooling tower
-Closed cooling water 8
-system 2 11
-Rain water system
-Desalination plant
-Water treatment plant 4 1 3
-Waste water system 9
-Fael gas supply system
-Fuel oil supply system
1 : Air compressor 7 : Steam turbine HMI: Human Machine Interface Remark:

2 : Combustion chamber 8 : Condenser : Information exchange For simplicity reasons only one line
3 : Gas turbine 9 : Condensate extraction pump : signal is represented for:
4 : Generator 10: Deaerator and feedwater : Actuation signal - Information exchange
5 : Exhaust gas flap or bypass 10: storage tank : Feedback signal - Commands
6 : Heat recovery steam boiler 11: Boiler feedwater pump BOP: Balance of Plant - Feedback informations
12: Supplementary firing CSXA403478.cdr
Figure 6: Basic Scheme of the Control of a Combined Cycle Power Plant (Typical)

CCPP Overview
Control and Protection Systems (continued)
EGATROL, ELECTRONIC GAS TURBINE CONTROL

• Is the proprietary name for the electronic gas turbine controller.
• Includes a sequencing program that automatically starts, “loads” and shuts
down the gasturboset and its auxiliaries while observing ALSTOM protective
limitations.
• Regulates during operation, the gasturboset by positioning the fuel control
valves based on electric power output requirements.
• Includes a human machine interface (HMI):
• For receiving data from the process.
• To influence the process.
• Activates the safety system.
• The latter one, when it is actuated, protects the gasturboset from damage by
tripping the fuel stop and control valves to their closed positions.
• This immediately:
• Stops the fuel throughput to the combustion chambers
• Interrupts the combustion process
• Shuts down the turboset
TURBOTROL, STEAM TURBINE CLOSED LOOP CONTROL

• Is the proprietary name for the steam turbine controller.
• Provides control and regulation of the steam turbines
• Performs its function by positioning the steam control valves.
• The latter ones regulate the steam throughput across the turbine, based on
system requirements
• Activates the safety system.
• The latter one, when it is actuated, protects the steam turboset from damage
by tripping the steam stop and control valves to their closed positions
• This immediately stops the flow of steam to the turbine
TURBOMAT, STEAM TURBINE SEQUENCER

• Is the proprietary name for the steam turboset sequencer.
• Is optional equipment.
• When supplied is used to automatically start-up, “load”, and shutdown the
steam turboset and its auxiliaries while observing ALSTOM limitations.

CCPP Overview
EXCITATION CONTROL
• Is the excitation system for the alternators.
• Includes a centrepiece that is the automatic voltage regulator (AVR). The latter
one:
• Maintains the outlet voltage of the generator at a constant value
• Influences the exciter and thereby the electric current through the windings of
the magnetic field
• Has a back-up manual field current regulator (FCR). The latter one:
• Fulfils the same task but requires manual input from the operator
• Adjusts the reactive electric power output of the generator, expressed in units
of volt-ampere reactive (V·Ar)
SYNCHRONIZING CONTROL
• Is the synchronizer of the turbosets.
• Can be operated automatically or manually
• Interacts with:
• Gas and steam turbine controllers
• Excitation control
• Matches the following parameters of the generators and the grid:
• Outlet voltage
• Frequency
• Phase sequence
When synchronization is completed, the generator breaker closes.
GENERATOR PROTECTION
The generator protection system:
• Protects the generator and its associated equipment from abnormal operating
conditions. When the protection equipment detects a fault:
• The generator breaker is opened
• The gas or steam control valves are tripped to their closed positions
• GSX, REG etc. are examples of protection systems in use.

CCPP Overview
HRSG CONTROL
Each HRSG has several function groups and drives.
The HRSG control comprises:
• The boiler controller.
• Coordinates different control functions of the HRSG like:
• Start-up
• Shutdown
• Open-loop controls
• This coordination is made in respect with the open-loop controls of the gas
and steam turbosets
• Regulates during operation, the HRSG's drum level closed-loop controls.
Miscellaneous Controller
The miscellaneous controller takes care of the different components of the water
steam cycle like:
• The condenser
• The condensate extraction pumps
• The deaerator
• The boiler feed water pumps
BOP Equipment Controller

BOP is the abbreviation for balance of plant.
Practically each BOP equipment has its own controller. To indicate that their
functions must be coordinated, the concept of the BOP equipment controller is
introduced.
AGC (AUTOMATIC GENERATION CONTROL)

The AGC:
• Is the over imposed power plant controller.
• Ensures that each major component in the CCPP process is brought into service
or removed from service in the proper sequence.
• Is also called UNITMASTER / BLOCKCONTROLER.
• Includes several HMIs:
• For receiving data from the process
• To influence the process

CCPP Overview
Test Questions for Verification of Learning Progress
General The following points are important and shall be taken into account:
• The training manual may be used (open book), but first try without looking up in
the manual.
• Mark the box in front of the correct statement with a diagonal cross.
Use this section to verify your learning progress! Review subjects, which are not
clearly understood.
Questions:
What is the main purpose of the heat recovery steam generator

Question 01:
(HRSG) in a combined cycle power plant (CCPP)?
A Producing desalinated, potable water
B Conversion of thermal energy to pressurized steam
Producing steam on one or more pressure levels used in a steam turbine

C or in industrial applications
D Cooling the auxiliaries (lube oil, generator, etc) by steam expansion
Question 02: What is the main purpose of the condenser in a CCPP?
To pre-heat the fuel gas / fuel oil in order to increase overall plant
A efficiency
To change the state of steam to water by a pressure increase when

B flowing through the condenser
To change the state of steam to water by heat removal when flowing

C through the condenser
D To re-heat the exhausted steam by exhaust gas from the gas turbine

CCPP Overview
Questions (continued):
Question 03: Inside the HRSG the pressure of the exhaust gas is:
A About the same pressure as the ambient pressure
B About 0.1 bar absolute
C Proportional to the load output of the gas turbine
Question 04: Water at a pressure of 80 bar boils at:
A 100 °C
B 275 K
C 275 °C
D 295 °C
Question 05: Exhausted steam in a steam turbine means steam with approximately:
A pabs = 1 bar, t = 100 °C
B pabs = 0.1 bar, t = 46 °C
C p = ambient pressure, t = 500 °C
D pgauge = 100 bar, t = 315 °C
In a CCPP the steam pressure at the inlet of the steam turbine results
Question 06:
from:
A Discharge pressure of the feed water pump(s)
B Reductions and orifices in the heat exchanger piping of the HRSG
C Discharge pressure of the condensate water pump
The expanded steam after evaporation (steam volume larger than water
D volume)

CCPP Overview
Question 07: In the generator(s) of a CCPP:
The electrical energy is supplied to the high voltage power line via the
A brushes
B The stator is designed to be used as a magnet
The terminal voltage is the same as the voltage of the power line
C (national grid)
D The rotor is designed to be used as a magnet
Question 08: The load output of the gas turbine is controlled by:
A The rotational speed of the turbine
B The excitation
Combination of exhaust gas mass flow through the turbine and

C temperatures before and after the turbine
In case of a failure in the steam turbine, the steam coming from the
Question 09:
HRSG:
A Is re-circulated directly to the HRSG
B Is blown in a water-filled tank
Is condensed by water injection, the condensate is directly conducted to

C the feed water tank
Is condensed by water injection, the condensate is directly conducted to

D the condenser

CCPP Overview
Question 10: Energy can:
A Be converted to any other form of energy (directly or after different steps)
B Be utilized technically only after at least one conversion
(By human beings) sensed only in form of pressure, kinetic or potential

C energy
D Be converted to an other form only via mechanical energy
E Not be stored
Question 11: Multi-shaft CCPP includes:
A One single generator
B At least two generators
C Always one speed reduction gear
D Never a bypass stack
Question 12: The step-up transformer in the gas turbine section is used to:
A Increase the voltage of the generator terminals (during load operation)
B Reduce the voltage of the generator terminals (during load operation)
Match the generator frequency to the frequency of the high voltage

C power line
Only for measurement of the electric power delivered to the high voltage
D line
Question 13: In case of a CCPP with single shaft design:
A The GT and the ST start simultaneously
B First the GT starts, later the ST starts
The generator is synchronized only when GT and ST have reached

C nominal speed

CCPP Overview
Lesson Test Questions Solution Key
The correct answers for each question are as follows:

01: C
02: C
03: A
04: D
05: B
06: A
07: D
08: C
09: D
10: A
11: B
12: A
13: B
Summary
This section described the components used to deliver electricity from modern gas
and steam turbine power plants.
Included information of how those single processes are joined to operate at higher
efficiency in a combined cycle arrangement to deliver only electricity or
simultaneously electricity and heat.
To ensure that you understand the material covered, review each of the objectives.


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Overview & Introduction Combined Cycle

Power Plant Overview

ALSTOM (Switzerland) Ltd ABCD

Power Plant Training Center

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

Power Plant Training Center

The O&M Documents are separated into:

Power Plant Training Center

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

• List the energy conversions in a combined cycle power plant.

Power Plant Training Center

Power Plant Training Center

Gas Turbine Power Plant

Electronic gas turbine

Exhaust gas Unit auxiliary

(Continued next page)

Power Plant Training Center

However, the energy conversion process from

Gas Turbine, Components and Functional Principle

Gas Turbine The gas turbine is composed of three processing elements:

(Continued next page)

Power Plant Training Center

Gas Turbine, Components and Functional Principle (continued)

Turbine The turbine

Power Plant Training Center

Generator, Components and Functional Principle

Generator The generator:

The generator rotor is coupled to the turbine rotor, either

Power Plant Training Center

Generator, Components and Functional Principle (continued)

Generator The generators bushings also called generator terminals.

The main step-up transformer:

The grid breaker (HV breaker):

Power Plant Training Center

Steam Turbine Power Plant

Steam turbine closed

(Continued next page)

Power Plant Training Center

Steam Turbine, Components and Functional Principle

Power Plant Training Center

Boiler, Components and Functional Principle

The boiler in a CCPP is called heat recovery steam generator (HRSG).

Boiler Sections A simple boiler includes a:

Power Plant Training Center

Water Steam Cycle, Components

Figure 3: Flow Diagram of a Single Pressure Cycle (Typical)

(Continued next page)

Power Plant Training Center

Water Steam Cycle, Components (continued)

Power Plant Training Center

Power Plant Training Center

Combined Cycle Power Plant for Delivery of Electricity

Low / intermediate Low pressure

Low pressure LP steam drum

Intermediate pressure IP steam drum

High pressure Intermediate pressure water

High pressure HP steam drum

(Continued next page)

A Producing desalinated, potable water

B Conversion of thermal energy to pressurized steam

D Cooling the auxiliaries (lube oil, generator, etc) by steam expansion

A About the same pressure as the ambient pressure

B About 0.1 bar absolute