Combined Cycle Power Generation -An Introduction

Combined Cycle Power

Generation

One Gas Turbine and One Steam Turbine. [without any additional fuel consumption]

Fully fired combined cycle

District heating and process heat for industry.

Bypass Stack / Waste Heat Recovery Systems

Combined Cycle Heat Flow

OUTPUT 30 % OUTPUT 16 %

100% FUEL INPUT

GT

67%

HRSG + ST

14% TO STACK

3% MISC LOSSES

34% CONDENSER LOSSES

3% MISC LOSSES

HRSG - Classification
HRSG

UNFIRED

SUPPLEMENTRY FIRED

VERTICAL

HORIZONTAL

DRUM TYPE

ONCE THROUGH

Heat Recovery Steam Generator [HRSG]

Typical two stage Combined Cycle

Water Steam Path

Cond. Preheater LP ECO HP ECO-I LP EVA LP SUP HP ECO-II
HP Drum

LP Drum

LPBFP HPBFP

LPCC pump

HP EVA

HPCC pump

HP SUP-I

HP Turbine

LP Turbine & Condenser

HP SUP-II

CEP

VERTICAL HRSG
Flue gas flow -vertical Water/ steam flow in horizontal finned tubes Small foot print area Added circulation Good cycling capability Replacement of tubes easily possible Easily access for inspections

VERTICAL HRSG
Flue gas flow -vertical Water/ steam flow in horizontal finned tubes Small foot print area Added circulation Good cycling capability Replacement of tubes easily possible Easily access for inspections

Horizontal HRSG
Flue gas flow-horizontal Water/ steam flow in vertical finned tubes Large foot print area Natural circulation In cycling duty problems in superheater/ reheater sections. Replacement of tubes not possible Access for inspections is difficult

SINGLE PRESSURE NON REHEAT

DOUBLE PRESSURE NON REHEAT CYCLE

DUAL PRESSURE CC PLANT

TRIPLE PRESSURE CC PLANT

Temperature Profile in a Waste Heat Recovery Boiler

Pressure Stages in WHRB

Criteria :
Maximum available Temperature at WHRB inlet Provision of Supplementary firing in WHRB Station owners own economic evaluation of Heat rate, Efficiency, Power output, Extra investment, Added O&M Cost

Pressure Stages in WHRB

Output (%) Single pr., Non reheat - 4.7 Two pr., Non reheat - 1.0 Three pr., Non reheat Base Three pr., Reheat + 0.7 Plant Eff. (%) - 4.7 - 1.0 Base + 0.7

Limiting Factor: Saturation temperature at particular pressure Possible degree of Superheat

Combined Cycle Parameters

PINCH POINT:
Difference between flue gas and water/steam temperature at evaporator section It is the minimum differential temperature between gas and water/steam in the Boiler Lower pinch point results in linear rise in cycle efficiency Lower pinch point results in exponential rise in boiler heat transfer area

Combined Cycle Parameters

PINCH POINT:
Every 10C decrease in Pinch Point, results in
q q q q HP steam flow increases by 4.6 % Steam turbine output increases by 3.4 % Heat rate improves by 20 kcal/kWHr Efficiency improves by 0.52 %

Optimum breakeven is 10 C, with regard to Heat Transfer area of Evaporator Pinch point at Dadri (HP Ckt) is 11.6C

(LP ckt) is 8.0 C

Optimum Approach & Pinch Point

Triple Pressure Levels Reduces Irreversibility & Increasing Heat Transfer

Triple Pressure CC Plant

Triple Pressure HRSG With SCR

SCR
Suitable temperature range 300 to 400 oC. 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.

Principle of DeNOx thru SCR

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, SO2 and requires no chemical injection.

Energy balance in diff scenario

Config GT GT HRSG Stack Condens ST ST Outpu Losse Losses losses er losses Losses output t s Single pr. 37.6 0.5 0.5 0.5 0.5 0.2 0.3 0.3 0.3 11.4 8.2 8.2 8.6 29.9 32.1 32.0 31.0 0.3 0.3 0.3 0.3 20.1 21.0 21.1 21.7

Double 37.6 pr. Triple pr. Triple, reheat 37.6 37.6

Finned Tubes

Single Shaft CC Plant

Single Shaft Plant Arrangement

Multi-shaft Arrangement

Single-shaft Arrangement

Single Shaft Combined Cycle Plant

Simplified Plant design and operation Lower initial investment Unitized design means problems faced in multi shaft configuration employing Triple Pressure Reheat ST are absent.

Single Shaft CC Units Dont Need

Main steam non return valves Cold Reheat isolation valves Cold Reheat Balancing valves Reheater relief valves Hot Reheat stop/ control valves Low pressure Non return valves Steam headers

Cost Reduction in Single Shaft Unit results from:

Reduction in number of Electric generators, step up transformers, and high voltage feeders. Civil works Single building, Reduced building height Reduction in number of valves and length of piping. Elimination of Bypass stack and diverter damper.

Limitations of Single Shaft Units

Need for higher starting power Less Operating Flexibility ; Option of phased construction and commissioning not available.

Single Shaft Unit Configuration

GT- Generator Clutch ST

GT ST Generator

GT-GeneratorClutchST config.

Steam turbine must be moved to remove and service the generator Rotor. Startup of gas Turbine is independent of Steam turbine SSS clutch allows load operation of Gas Turbine in case of outage of the ST Gas turbine and steam turbines have their own thrust and journal bearings

GTSTGenerator Configuration
Axial steam turbine exhaust is not possible Steam turbine shares the cold end thrust / journal bearing of Gas Turbine Auxiliary steam is required for cooling of steam turbine during startup
Outage of ST necessarily lads to outage of the whole power train.

Gas Turbine is accessible for maintenance only after cool-down of complete power train.

Combined Cycle Options

STEAM CYCLE: Single pressure Two pressure Three pressure Reheat Non-reheat HRSG DESIGN: Natural circulation evaporator Forced circulation evaporator Unfired Supplementary fired

NOx CONTROL: DEAERATION: Water Injection Deaerating condenser Steam Injection Deaerator/evaporator SCR ( NOx and/or CO) integral with WHRB Dry Low NOx Combustion

Combined Cycle Options

CONDENSER: Water cooled (once through system) Water cooled (evaporative cooling tower) Air Cooled condenser) FUEL: Natural gas Distillate oil Ash bearing oil Low Btu coal and oil-derived gas Multiple fuel system

Cost Distribution for a CC Power Plant

(2GTs + 2HRSGs + 1ST)

bine, Aux equipment : 26 % + piping + auxiliary equipment: 17 turbine + generator+piping+condenser: and supervisory equipment+transforme gineering: 6% n + supervision: 18 %

Bypass Stack / Waste Heat Recovery Systems

Power Enhancement Methods

It is Site specific and dependant on:
Site ambient temperature Level of desired output enhancement Anticipated Operational hours Water availability Structure of Power Purchase Agreement Allowable plant emission Owners own economic evaluation factors for plant output, heatrate, O&M costs.

Co st of

0.2 1

0.4

0.6

0.8

1.2

1.4

Ins tal lat ion

0
0 .6 0 .4

O& M Co st

O& M

Thermal

Comb. Cycle

0 5 .5 0 3 .7 0 6 .4 0 5 .3 0 5 .6

Coal fired Vs. Combined Cycle

St aff Fu el Re qu ire m en La t nd re qu ire m W en ate t rR eq uir em en t Ge sta tio n Pe rio d Pl an tE ffic en cy

1 7 .3

Comparison of Availability, Reliability

Availability = [Total Operating Hours Planned outage-Forced outage]/ Total Operating Hours Reliability = [Total Operating Hours Forced outage]/ Total Operating Hours

Typical Figures Plant types Gas turbine (gas) Steam Turbine (coal) Comb cycle (gas) Nuclear Diesel generator Availability 88-95 82-89 86-93 80-89 90-95 Reliability 97-99 94-97 95-98 92-98 96-98