Overiew of Comb Cycle Rev 7.0 - Part 1

Gas Turbine Power
Generation
-An Introduction
Animated Gas Turbine Parts
Combined Cycle Power Generation
World Electricity Generation by Fuel Source
YEAR - 1995 YEAR - 2020
INTERNATIONAL ENERGY AGENCY
OVER THE YEARS GAS TURBINES AND COMBINED CYCLE PLANTS
HAVE BEEN GAINING IN POPOULARITY
Efficiency Of Different Technologies
CC Plants - Preferred Technology
70 % of post 2000 Generating capacity addition in US
has come from Gas Turbines and CC Plants.
Last decade has witnessed that majority of UKs very
old coal fired power plants have been replaced by CC
Plants.
For Countries like Japan & Korea with limited fossil fuel
resources, preferred technology is combined cycle.
In India share of GT and CC Plants in total installed
capacity is less than 10 % but 80% of the power plants
set up by IPPs are combined cycle plants.
Availability of Natural Gas/ LNG and CC Plants have to
play an important role if Short/ Intermediate Term
Capacity addition targets are to be met.
LIFE CYCLE COST OF A CC PLANT
1 2% INCREASE IN EFFICIENCY JUSTIFIES 3 5 % HIGHER
INITIAL CAPITAL INVESTMENT.
Combined Cycle Power Generation
Earliest example of harnessing jet propulsion
for having Rotary motion.

Invention of Aeolipile in 150 BC
Originator is Hero of Alexandria, Egypt
Initial Concept of Engine
Requirement from a Prime Mover

Less no of Links
Vibration free
Maintenance free
Less complicacy
Boost of power
Compact
High speed
Cheap
Improvement over the Years
1765 : Reciprocating Steam Engine
by James Watt

1876 : Reciprocating IC Engine
by Nikolaus Otto

1883 :Steam Turbine
by De Laval

1884 : Steam Turbine
by Charls Parson

1908 : First Gas Turbine
by Korting AG/BOSCH
1940 : First Stationary Gas Turbine
Turbine as Prime Mover
Most Satisfactory machine:

Absence of Reciprocating & Rubbing Members
Less Balancing problems
Very low Lub Oil consumption
Very high degree of reliability

Most sought after since beginning of the Century
Use for Moving and Stationary prime movers,

BUT REQUIRES

High Pressure & temperature steam
Bulky & expensive steam generating equipments
Different working fluid for Boiler & Turbine
Lengthy/complicated starting & stopping
procedures

Necessity of direct working fluid like IC engines
Absence of Thrust of Power
Steam Turbine as Prime Mover
Developed during World war for aircraft
propulsion
Introduced in 1940s to the power generation
By 1960s, established as peak power producer
Initial development for mechanical drives in
Pipeline pumping station
gas compressors
transportation
Gas Turbine as Prime Mover
Simple Gas Turbine
Joule Brayton Cycle
Gas Turbine with Regeneration
Gas Turbine with Intercooling
Gas Turbine with Reheater
GT with Intercooling & Recuperation
Open Cycle Gas Turbine for Power Generation
Where the Generator is Kept?
Industrial Gas Turbine
Industrial Gas Turbine
Gas Turbine Rotor
Gas Turbine Rotor
M501F/M701F Gas Turbine (MHI)
FUEL
(100 %)
POWER (30 %)
MISC.
(3 %)
EXHAUST
HEAT
(67 %)
Heat Balance In Gas Turbine
Gas Turbine Requirements
Factors for a Gas Turbine
v High efficiency
v High specific output

Key Parameters affecting above:
v Firing temperature

v Pressure Ratio
Higher TIT
Each 55
o
C increase in TIT improves Output by 10-
13 % and Efficiency by 2-4 %.

TIT for Modern Gas Turbines > 1400
o
C

Higher TIT demands :
a. Creep Rupture Strength,
b. Fatigue Resistance to cyclic loadings,
c. Castability and Machinabilty,
d. Phase Stability
GT Blades: Internal Cooling Passage
Turbine Rotor blades
Air for Blade cooling
Air for Blade cooling

The firing temperature is raised from
1104
o
C to 1124
o
C

Interior & Exterior Cooling-air Circulation
Film Cooling & Impingement Convection Cooling
Single And Multipass Cooling
Blade Cooling
Impingement, Convective, and Film Cooling
for First Stage Blades.

Impingement cooling for rest stages.

Serpentine passages with turbulence
promoters

Multipass, turbulated, pin fin cooling holes
have replaced span wise film cooled design.

Rotor Air Cooler Heat Utilization
Cooling by air is detrimental to cycle efficiency
because of irreversible pressure losses,
reduction in gas path temp.,and internal
losses.

Closed loop steam cooling by convective heat
transfer avoids above losses.

Yields a 2 % power increase in Efficiency.

In H-class, GT is used as parallel IP reheater
for the bottoming cycle.
Closed Loop Steam Cooling
Cooling by air detrimental to cycle efficiency because of
irreversible pressure losses, reduction in gas path temp., and
internal losses.
Closed loop steam cooling by convective heat transfer avoids
losses and yields a 2 % increase in Efficiency.

Firing Temp. Trend & Material Capability
MHI J class has TIT of 1600
0
C.
Effect Of Cooling On TIT
MHI J class has TIT
of 1600
0
C.
Advances in Blade Metallurgy
Conventional GT Blades - Vacuum precision
casting methods, employ segregated hardening
by alloying elements.

Directional Solidification

Single Crystal Blades

ODS Ceramics

Corrosion Resistance Coatings

Thermal Barrier Coatings
Microstructure of Advance Materials
Directional Solidification
Grain boundaries reduce creep strength,
particularly when traverse the direction of
primary stress.

DS allows the grain-lines to be aligned
parallel to the blade axis.

DS allows blades to operate at 25 K higher
temperature than conventionally cast blades.

Service life in terms of thermal fatigue
increases by a factor of 5.
Single Crystal Blades
SCBs are blades without grain boundaries.

Further 25 K temp. increase can be gained.

Molten material is solidified in the form of
columnar grains from which a single
selected crystal is grown.

Preferred orientation along the longitudinal
axis of the blade.

Length and weight limitation.
ODS Ceramics
Oxide Dispersion Strengthened Ceramics

Strength remains approximately constant
upto 1000 C, though less than Ni based
alloys.

ODS is suitable for Solid and Slightly
cooled stationary blades.

Complex manufacturing methods to
produce intricate shapes.
Anti Corrosion Coatings
Upto 800 C - Cr based diffusion coatings.
MCrAlY (M-Co and /or Ni) coatings for higher T.
Aluminium forms dense oxide layer on the
coating surface that is thermally very stable.
Other materials control Al activity, hold the
oxide layer in place and adapt the coating to
the base.
MCrAlY coatings are applied using the vacuum
plasma spray process. Thickness must not be
more than 0.40 mm. Refurbishment after 20-
25K hours.
Thermal Barrier Coatings
TBC allows the operating temperature to be
increased by 100 K.
Outer Ceramic Layer - Zirconia, thickness
limited to 0.25 mm.
Metallic bonding layer - MCrAlY
Flaking - due to transient stresses between
the inner and outer surface of ceramic.
Peeling - Oxide growth on bonding layer.

Two principal methods of application -
Thermal Spraying (atmospheric plasma)
& Physical Vapour Deposition (PVD).

PVD yields better result but much more
costlier.

Stator blades - Thermal Spraying

Rotor Blades - PVD

Thermal Barrier Coatings CONTD.

TBC
Working
Principle
Firing Temperature &
Efficiency in GE Combined-Cycle Plants
(Source: General Electric R&D).
GT-Thermodynamic Fundamentals
For a given TIT higher Compression Ratio
yields higher efficiency.
Optimum compression ratio for maximum
Efficiency and maximum Specific Output
are different.
Optimum r for max. sp. Work Output
corresponds to the value for which
compressor and turbine outlet temperature
are equal.
Performance
q
Pr. Ratio
|
.
|
\
|
|
|
.
|
\
|
=
1
2
1
1
1
P
P

q
1 14 7
q
Specific Output, MW / kg/sec
Pressure Ratio = 5
10
15
20
Max. Shaft O/p
Max. Thermal Eff.
Performance
Performance
Efficiency of Simple and Combined-Cycle Gas Turbines
Factors Affecting GT Performance
Ambient Temperature
Altitude above Mean Sea Level (MSL)
Relative Humidity
Inlet Pressure Loss
Exhaust Pressure Loss
Performance degradation
Steam /Water Injection for NOx Control
Type of Fuel
TYPICAL
Effect of Ambient Temperature
A 28C results in :
~ 25 % output reduction and
~ 10 % higher heat rate.
TYPICAL
Effect of Ambient Temperature
A 28C results in* :
~ 25 % output reduction and
~ 10 % higher heat rate.
Evaporative Cooling
Base Case 40C, 32% RH, Natural Gas Fuel, LHV 50,047 KJ/Kg
Inlet Pressure loss 10 millibar; Exhaust Pressure Loss 12 millibar
PARAMETER GE 6541B
Base Case
GE 6541B with
Fog Cooling
GE 9171E
Base Case
GE 9171E with
Fog Cooling
O utput, kW 31,749 35,318 101,510 113,100
Heat Rate, kJ/kWh 12,007 11,674 11,358 11,054
Compressor Inlet Temp,
?
C 40 26 40 26
Pressure Ratio
10.66 11.26 11.1 11.78
Compressor Discharge
Pressure, (Bar)
10.64 11.26 11.1 11.78
Air Mass Flow, Kg/sec 122.7 128.9 363.5 382.9
EGT, ?
557 548 564 553
Fuel Flow Rate, Kg/sec 2.116 2.288 6.399 6.939
Turbine Inlet Temp,
?
C 1100 1100 1124 1123
Axial Compressor Work,
kW
42,596 45,286 129,870 137,560
Turbine Section Work, kW 76,564 82,907 234,930 254,44
Thermal Efficiency, % 29.98 30.84 31.7 32.57
GT Specific Power,
kW/Kg/sec
15004 15436 15864 16299
Heat Rate for Incremental
Power kJ/kWh
-
8,712 - 8,391
Fuel Savings for
Incremental Power, %
- 27 - 26

Two Gas Turbines with /Without Fogging
Effect of Altitude
At 1000 meter
elevation the gas
turbine output is
15 % lower than
at sea level

TYPICAL
Effect of Humidity
* 4 inches H2O inlet drop produces :
1.50 % power output loss
0.50 % heat rate increase
1.2 F exhaust temp. Increase

* 4 inches h2o exhaust drop produces :
0.50 % power output loss
0.50 % heat rate increase
1.2 F exhaust temp. Increase
INDICATIVE FIGURES
015
TYPICAL
Effect of Inlet Pressure Drop
TYPICAL
016
Effect of Steam Injection
TYPICAL
Effect of Evaporative Cooling
TYPICAL
018
Self contained power package Units
Provided under supplier under single contract
Stanadardised product line/assembly line
Quick & easy installations
Low capital cost & fast installation
Higher operating costs in Open cycle but high
overall efficiency in Combined cycle
Good cycling capability
Lower pollutant emission
Lower pollutant emission
Lower installed cost
More compact site
Clean fuel source
No ash disposal
No coal handling cost
Lower O&M cost
Lower manpower
Phase wise construction
Why not have Gas Turbine
everywhere?

Map of
GAIL's
Pipelines
in India
HBJ pipe line
covers Gujarat,
Madhya Pradesh,
Rajasthan, Uttar
Pradesh,
Haryana and
Delhi, traversing
a total of 2,688
km.

Higher fuel cost
Uncertain long term fuel supply
Output more dependant on Temperature

Gas Turbine Fuels
DISADVANTAGES OF LIQUID FUEL
COMMERCIAL REASON:
Liquid fuels are costlier than gaseous fuels.

Gas Turbine Fuels NCV,
Kcal / kg
Price
Rs / kg
Heating value/ Price
kcal / Rs
Natural Gas
9885 21.70 455.5
HSD
10300 30.2 341.0
Naptha
10500 35.92 292.3
Kerosene
10215 30.94 330.2
Heavy distillate
9832 24.91 394.1
Residual oil
9760 24.91 391.8

CUMBERSOME ARRANGEMENT:
Liquid fuels requires extra arrangement for
transportation.
OPERATIONAL PERSPECTIVE
Requires running of more auxiliaries.
Reduced capacity in Open cycle and comb cycle
Reduced Efficiency.
Increased safety risks
More Manpower.
MAINTENANCE FREQUENCY:
More inspection of Hot gas path components.
More equipments to maintain.
This translates to costly outages, costly
replacements and costlier unscheduled outage
hours.
ENVIRONMENT PERSPECTIVE
More NOx
Oil spill etc.
MERITS OF LIQUID FUEL
INCREASED AVAILABILITY
# When Fuel gas is in shortage
# Where Power is required, no gas is available.
# Increasing power demand Vs availability of Gas

1. M/c doesnt remain ideal in case of short term
gas unavailability and continues ROI.
2. Generating capacity can be enhanced within
short time with liquid fuels.

UNDESIRABLE QUALITIES OF LIQUID FUEL ARE BECAUSE OF
INHERENT DEFICIENCY

Liquid state
High viscosity
Tendency to polymerize
Incompatibility with other
fuel oils
High carbon content
leading to carbon deposits.
CONTAMINATIONS

Corrosion of hot gas path
components due to
Vanadium compounds
Corrosive sulfates with
sulfur and alkali metals
Built up of ash on nozzle
blades

Tackling Inherent Deficiencies

Increased safety precaution

Heating of Fuel oil pipe lines, storage
tank with steam tracing
TACKLING CONTAMINATIONS

Clean Fuel
Treatment Of Fuels
Additives
Turbine Washing

Major Components
Starting system
Inlet Air System
Compressor
Combustion system
Silo type
Multiple Canular
Annular
Turbine
Exhaust system
Generator
Bypass Stack system
Waste Heat recovery System
Starting System
1. SFC : Starting Frequency Converter

2. External Motor Driven
Typical power requirement :
2 MW for 150 MW Gas Turbine
Air Intake Filter Housing
Typical Installation
Different
Types of
Filters
Typical Installation
Inlet System
It consists of following parts

1. Filter compartment.
2. Duct.
3. Silencer.
4. Lined elbow.
5. Transition piece.
6. Inlet plenum.
7. Expansion joints.
Filter Cleaning
Erosion

Corrosion

Fouling

Plugging

Filtration Media
No of air filters 1144 [ 4 * 132 + 4 * 154 ]
No of solenoid valves 176
Surface area of each cartridge 25 m
2
Filtration efficiency 99. 8 % [3], 99 % [1 ]

Filter diff pressure Fresh ones 3.5 mbar
Start of pulse 7.5 mbar
Stoppage 5.5 mbar
Alarm 30 mbar
Collapse 250 mbar

Duration pulse air flow: 0.1 sec
Interval between two pulses 3.1 sec
Typical Values- Dadri Air filters
It ingests a huge amount of air - particulate matter,
hydrocarbons aerosols and other organic compounds
and gases of industrial production eg nitrogen,
chlorine and sulphur.

The fine particulate matter & other compounds are
deposited on the compressor blades.

This alters the aerodynamic profile of the blades and
leads to a fall in compressor efficiency (because of
thickening of boundary layer air stream)
Why Compressor Cleaning ?
Thicker boundary layer results in
Reduced mass flow through the Compressor
Reduced compression pressure gain and
therefore lesser pressure ratio.

Compressor fouling reduces the compressor
isentropic efficiency, resulting in more power
for compressing the same amount of air
Why Compressor Cleaning ?
Washing restores engine efficiency that
would otherwise be lost by fouling.
Effect of Filter Cleaning on GT Output
The compressor blade
before cleaning
The compressor blade after
cleaning
The liquid follows the air stream into the
compressor, where the mechanical
movements and chemical act of the washing
liquid releases the deposits.
Washing can be done off-line and on-line
Off-line washing:
Low air velocities allows washing liquid to move
around in the compressor and slowly find its way
towards the exhaust end.
The washing result is usually very good (~100 %).
How Compressor Cleaning is Done?
On-line washing:
Centrifugal forces pushes the liquid out to the
periphery where it can do no cleaning job.
High air velocity results in a short retention time
for the liquid through the compressor.
Strong Air turbulence results in liquid being lost to
the duct walls before entering the compressor
Compression results in a temperature increase
inside the compressor, and liquid may start to boil
off about halfway through the compressor.
Often causes erosion damage to compressor blades

On-line washing:
Way around is to wash with droplets having a
smaller diameter with help of high pressure
atomisation (70 bar)
Droplet volume is a function of radius cubed, i.e. a
droplet of half the size has only one eighth of the
volume and thereby only one eighth of the mass
and impact force.
The liquid penetrates into the core air stream and
relatively little liquid is lost to the walls.
On-line washing:
Spray droplets will have almost the same velocity
as the air entering the compressor and are
therefore more likely to penetrate deep into the
compressor. This is known as a high droplet-to-air
velocity ratio.
The high-pressure system, also referred to as a
'direct injection system', results in fewer nozzles to
install as the liquid capacity per nozzle is higher
compared to a low-pressure system. This also
reduces installation and maintenance costs.

http://www.jxj.com/magsandj/cospp/2004_01/turbine_efficiency.html
Nozzle Spaying Washing Liquid
Nozzles around the Compressor Inlet
(Blue Hose)
Compressor Wash Pump Skid
Mixing Tank
Control system
High pressure pump
Pnuematic 12 tyres
Claims of a Typical Compressor Washing
Liquid Producer
30
32
34
36
38
40
E
f
f
i
c
i
e
n
c
y

(
%
)
c
o
m
p
e
t
i
t
o
r

c
o
m
p
e
t
i
t
o
r

c
o
m
p
e
t
i
t
o
r

c
o
m
p
w
a
s
h
Ef f iciency Comparison Between Bef ore and Af ter
Cleaning
Before Cleaning
After Cleaning
150
160
170
180
190
200
210
M
W

O
u
t
p
u
t
c
o
m
p
e
t
i
t
o
r

c
o
m
p
e
t
i
t
o
r

c
o
m
p
e
t
i
t
o
r

c
o
m
p
w
a
s
h
MW Comparison Between Before and Aft er Cleaning

Before Cleaning
Af ter Cleaning
Design
Liquid Producer
Liquid Producer
10000
10200
10400
10600
10800
11000
11200
H
e
a
t

R
a
t
e

(
K
J
/
K
W
H
)
c
o
m
p
e
t
i
t
o
r
c
o
m
p
e
t
i
t
o
r

c
o
m
p
e
t
i
t
o
r
c
o
m
p
w
a
s
h
Heat Rate Comparison Between Before and Af ter Cleaning
Before Cleaning
Af ter Cleaning
Design
Liquid Producer
10
11
12
13
14
15
C
o
m
p
r
e
s
s
o
r

R
a
t
i
o

c
o
m
p
e
t
i
t
o
r

c
o
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p
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t
i
t
o
r

c
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i
t
o
r

c
o
m
p
w
a
s
h
Compressor Ratio Comparison Between
Before and Aft er Cleaning
Before Cleaning
Af ter Cleaning
Low-pressure system-offline & on-line washing
typically up to 9 bar atomizing pressure

many nozzles required (low capacity per nozzle

small nozzle orifice may result in clogging

risk for liquid streaking (low liquid exit velocity from nozzle)

separate set of nozzles for on-line and off-line

small risk for nozzle wear
low pump power

High-pressure system -
typically 70 bar atomizing pressure
low installation and maintenance cost (few nozzles to install)

less liquid is used
good on-line liquid penetration (high liquid-to-air velocity
ratio)

small risk of erosion damage (less than 100 micron droplet
size)

easily retrofittable
same nozzles for off-line and on-line

Combustion -Aims
CO, UHC, and NOx emission reduction.
Attaining high inlet temperature
Flame Stabilization and Combustion Efficiency
Reducing Pressure losses in CC.
All above lead to lean premix combustion,
reduced resident time, and increased
turbulence.
Annular or Canannular combustors are more
suitable than Silo type combustion chambers.
Typical Gas Turbine Installations
Typical section of Combustion Chamber
Typical Silo type
combustion chamber
Silo type
combustion
chamber with
Primary and
Secondary air

Primary air: 30 %
Secondary Air:65 %
Blade cooling: 5 %
24 Burners in a Hybrid-Burner-Ring (HBR) Combustor

GAS TURBINE A SIMPLIFIED SCHEMATIC DIAGRAM
Multiple Canular Combustion System
Siemens 501G Turbine
COMBUSTION -AIMS
GAS TURBINE COMBUSTION OBJECTIVES
- CO, UHC, and NOx emission reduction
- Attaining high inlet temperature
- Flame Stabilization
- High Combustion Efficiency
- Minimum Pressure Loss
ABOVE OBJECTIVES ARE ATTAINED BY
- Lean premix combustion
- Reduced resident time, and
- Increased turbulence.
Annular or Canannular combustors are more
suitable for achieving above as compared to Silo
type combustion chambers.
Gas Turbine Exhaust Emissions
NOx and SOx Emission Limits
Advances In Combustion
Dry Low NOx (DLN) Combustion
Lean Premix Prevaporizing (LPP)
Combustion
Rich Burn, Quick Quench, Lean Burn
Combustor (RQL)
Catalytic Combustion
Dry Low NOx Combustion
Diffusion Combustion - Fuel injection and Air
flow separate, burning of heterogeneous
mixture.
A mixture of equivalence ratio less than 0.8
keeps the temperature lower than 1650
o
C.
Combustion is conducted in multiple locations
with precise sequencing and metering of both
fuel and air to specific points along the
combustion path.
NOx level achieved is less than 25 ppm (09
ppm also achieved).

Auxiliary Systems
Lub oil system
Hydraulic Oil system
Turbine Cooling air system
Fuel system
NOx Control system
Fire protection system
Compressor wash system

Post Combustion Pollution Control
SCR: NOx is converted into nitrogen
and water vapour by injecting
ammonia in presence of a catalyst.

SCONOx: Single catalyst for removal
of CO, NOx, VOCs, SO
2
and
requires no chemical injection.
Principle of DeNOx thru SCR
SCR
Suitable temperature range 300 to 400
o
C.
Segments having honeycomb patterns
containing catalyst is arranged within HRSG.
Ammonia slip is a concern, requires
sophisticated control system for controlling
injection.
Excessive Size and Weight.
Costly as compared to primary methods.
Sensitive to fuels containing more than 1000
ppm of sulfur.
H-Technology
The Next generation technology
Firing temperature raised to 2650 deg F
Novel features
Steam Cooling
CCP efficiency barrier of 60% crossed
Single shaft CCP configuration 480MW
Reheat Combined Cycles
10% reduction in operating costs

Biggest Gas Turbine SGT5-8000H
Gas Turbine: 340 MW
Weight 444 t
Steam Turbine: 190 MW
Manufacture: Siemens
GT
39 %
cc
60 %
Fuel N Gas
Air flow 800 kg/s
Blade Air cooled, Ni alloy
Ceramic coated
Single crystal,
approx 15 kg
Exhaust temp 600
0
C

Country Bavaria
Operating date: Dec 27, 2007

Typical GE Configuration
M701G2 at TEPCOs Kawasaki Power Plant, Japan

GT 334 MW, 21:1 Pr ratio, 14 stage compressor
TIT 1500
0
C,
Exhaust 588
0
C
1 GT+ 1
ST
498 MW
GT LCV
39.5%
ST LCV
59.3%
MHI Machine

Steam cooled comb liners, stage 1 & 2 stationary blades,
Single crystal blades
Alstom Range

Overiew of Comb Cycle Rev 7.0 - Part 1

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