220242en - CCPP Concepts PDF

Combined Cycle Power Plant Operation
Combined Cycle Power Plant Concepts Training Lesson
ALSTOM (Switzerland) Ltd
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CCPP Operation
Combined Cycle Power Plant Concepts
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 2007 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.
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Table of Contents
CCPP Operation
Document Reference ........................................................................................................................... 5 Typical Documents ........................................................................................................................... 5 O&M Documentation ....................................................................................................................... 5 Lesson Objectives................................................................................................................................ 6 The Combined Cycle Process ............................................................................................................... 7 Basic Combined-Cycle Concepts....................................................................................................... 8 Single-Pressure Cycle ....................................................................................................................... 9 Single-Pressure Cycle with a Preheating Loop in the HRSG ............................................................... 13 Dual-Pressure Cycles...................................................................................................................... 17 Triple-Pressure Cycle ...................................................................................................................... 23 Reheat Cycles ................................................................................................................................ 27 Cycles with Supplementary Firing .................................................................................................... 35 Summary of Cycle Performance ...................................................................................................... 39 Exercises Combined Cycle Power Plant Concepts ............................................................................. 40 HRSG Energy / Temperature Diagram.......................................................................................... 40 Energy Flow Diagram.................................................................................................................. 41 Summary .......................................................................................................................................... 42 Objectives Review .......................................................................................................................... 42

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Table of Figures
CCPP Operation
Figure 1: Energy/Temperature Diagram for an Idealized Heat Exchanger ............................................. 7 Figure 2: Flow Diagram of a Single Pressure Cycle .............................................................................. 9 Figure 3: Energy/Temperature Diagram for a Single Pressure HRSG ................................................... 10 Figure 4: Heat Balance for a Single Pressure Cycle ............................................................................ 11 Figure 5: Energy Flow Diagram for the Single Pressure Combined-Cycle Plant..................................... 12 Figure 6: Flow Diagram of a Single Pressure Cycle with LP Preheating Loop for High Sulfur Fuels ......... 13 Figure 7: Effect of Live Steam Pressure and Feedwater Temperature .................................................... 14 on Available Heat Compared to Required Heat in Preheating Loop...................................................... 14 Figure 8: Heat Balance for a Single Pressure Cycle with LP Preheating Loop ........................................ 15 Figure 9: Energy/Temperature Diagram for a Single Pressure HRSG ................................................... 16 Figure 10: Flow Diagram of a Dual Pressure Cycle for High Sulphur Fuels .......................................... 17 Figure 11: Effect of Feedwater Temperature and Number of Preheating Stages on Steam Turbine Output of a Dual Pressure Cycle............................................................ 18 Figure 12: Flow Diagram of a Dual Pressure Cycle for Low Sulphur Fuels............................................ 19 Figure 13: Heat Balance for a Dual Pressure Cycle with Low Sulfur Fuel .............................................. 20 Figure 14: Energy Flow Diagram for the Dual Pressure Combined-Cycle Plant .................................... 21 Figure 15: Energy/Temperature Diagram for a Dual Pressure HRSG ................................................... 22 Figure 16: Flow Diagram of a Triple Pressure Cycle ........................................................................... 23 Figure 17: Heat Balance for a Triple Pressure Cycle ........................................................................... 24 Figure 18: Energy/Temperature Diagram for a Triple Pressure HRSG.................................................. 25 Figure 19: Energy Flow Diagram for the Triple Pressure Combined-Cycle Plant ................................... 26 Figure 20: Flow Diagram of a Triple Pressure Reheat Cycle ................................................................ 28 Figure 21: Heat Balance for a Triple Pressure Reheat Cycle ................................................................ 29 Figure 22: Temperature / Entropy Diagram Showing the Effect of Full Reheat on the Steam Turbine Expansion Line ................................................................................................................ 30 Figure 23: Energy Flow Diagram for the Triple Pressure Reheat Combine-Cycle Plant .......................... 30 Figure 24: Energy/Temperature Diagram for a Triple Pressure Reheat HRSG....................................... 31 Figure 25: Flow Diagram of a High Pressure Rehaet Cycle with a HP Obe Through and a Drum Type LP Section........................................................................................................................ 33 Figure 26: Heat Balance for a dUal Pressure Reheat Cycle with Once Through HRSG .......................... 34 Figure 27: Energy/Temperature Diagram .......................................................................................... 36 Figure 28: Effect of Temperature after Supplementary Firing............................................................... 37
Table of Tables
Table 1: Performance Comparison for Different Cycle Concepts (Natural Gas Fuel with Low Sulphur Content)........................................................................ 39

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Document Reference
Typical Documents
CCPP Operation
Typical documents clarify the aspects described in this lesson which may not show project specific contents, therefore deviations to the specific installation are possible. All typical documents are referenced in the lesson and clearly identified.
O&M Documentation
O&M Documents are plant specific and form an important part of each training course. The training material includes most relevant O&M Documents and provides a basis for exercises and personal notes, markings, etc. The most relevant documents for the operation training are as follows: P&IDs with legend System descriptions Operating instructions Operating diagrams Instrument lists Set point lists
The O&M Documents are separated into: System specific documents Overall plant specific documents The system specific documents are attached to each lesson, whereas the overall plant specific documents are found in separate sections at the end of the training manual.

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Lesson Objectives
CCPP Operation
Upon completion of this lesson, the trainee is able to: Explain the differences between single-, dual-, triple pressure with and without reheat on hand of a sketch drawn from memory. Summarize the consequences (positive, negative) of supplementary firing. Explain the energy flow diagram of a single- dual- and triple pressure cycle with and without reheat and name approximate energy flow figures. Summarize the energy / temperature diagram of a single-, dual and triple pressure HRSG with and without reheat. Summarize the benefits of full reheat on the steam turbine expansion line in the temperature (entropy) enthalpy diagram.

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CCPP Operation
The Combined Cycle Process

The main challenge in combined-cycle plant design with a given gas turbine is how to transfer the gas turbine exhaust heat to the water/steam cycle to achieve optimum steam turbine output. The focus is on the heat recovery steam generator (HRSG) where the heat transfer between the gas cycle and the water/steam cycle occurs.
Dt = Constant
Temperature
CSXA401793
Energy Transfer
Figure 1: Energy/Temperature Diagram for an Idealized Heat Exchanger
Figure 1 shows the energy exchange in an idealized heat exchanger in which the product, mass flow times specific heat capacity, or the energy transferred per unit temperature remains constant in both media at any given point to prevent energy and exergy losses. In order for energy transfer to take place, there must be a temperature difference between the two media. As this temperature difference tends towards zero, the heat transfer surface of the heat exchanger tends towards infinity and the exergy losses towards zero. The heat transfer in an HRSG entails losses associated with three main factors: The physical properties of the water, steam and exhaust gases do not match causing exergetic and energetic losses. The heat transfer surface cannot be infinitely large. The temperature of the feedwater must be high enough to prevent corrosive acids forming in the exhaust gas where it comes into contact with the cold tubes. This limits the energy utilization by limiting the temperature to which the exhaust gas can be cooled.
(Continued next page)

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CCPP Operation
The Combined Cycle Process (continued)

The extent to which these losses are minimized (and the heat utilization maximized) depends on the concept and on the main parameters of the cycle. A more complex cycle uses the heat more efficiently, improving the performance but also increasing the cost. In practice, a compromise between performance and cost is ideal.
Basic Combined-Cycle Concepts
This section explains the most common combined-cycle concepts starting with the most simple and leading to more complex cycles. A heat balance for each of the main cycle concepts is given, based on the following: Cooling Air Coolers Ambient air temperature 15 C (59 F), ISO conditions Ambient air pressure 1.013 bar (14.7 psia) Ambient air relative humidity 60% Condenser vacuum 0.045 bar (1.3 Hg) Gas turbine type GT24B with sequential combustion, rated at 178 MW Steam turbine with water cooled condenser
The gas turbine is equipped with cooling air coolers that generate additional steam for the water/steam cycle and boost the steam turbine output. Because these features are the same for all of the heat balances, a clear comparison shows how the cycle concept influences the heat utilization. Additionally, an analysis for each concept shows how the main cycle parameters such as live-steam temperatures and pressures and HRSG design parameter influence the cycle performance. In combined-cycle design with a given gas turbine, the free parameters are those of the steam cycle. Therefore, in order to improve overall cycle efficiency, the influence of the various parameters is analyzed with respect to the steam turbine output. Without additional firing, the gas turbine exhaust supplies the thermal energy to the steam process. Since the efficiency of the steam process is proportional to the steam turbine output, the maximum efficiency improvements due to steam optimization are limited to the 30% to 40% of the total combined-cycle power output associated with the steam turbine. Although the cycles shown have only one gas turbine, the concepts and results are also valid for cycles with several gas turbines and HRSGs of the same size.
Cycle Parameters

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Single-Pressure Cycle
CCPP Operation
11 14 12 5 4 13 6 3
Natural Gas 7 8 1 2 G
1 2 3 4 5
Air Compressor Turbine (Gas) Superheater Evaporator Economizer
6 7 8 9 10
Drum Steam Turbine Steam Turbine Bypass Condenser Condensate Pump
9 11 12 13 14 Feedwater Tank/Dearator Feedwater Pump Gas Turbine Cooler Pegging Steam Line
10
CSXA401808.cdr
Figure 2: Flow Diagram of a Single Pressure Cycle
The simplest type of combined-cycle is a basic single-pressure cycle, In this case, the HRSG generates steam at only one pressure level. A typical flow diagram (Fig. 2) shows a gas turbine exhausting into a single HRSG. The steam turbine (7) has a bypass (8) into the condenser, which accommodates the steam if it cannot be admitted to the steam turbine (e.g., during start-up or because the steam turbine is out of operation). After the condenser (9), a condensate pump (10) sends the condensate back to the feedwater tank/deaerator (11). The feedwater pump (12) returns the feedwater to the HRSG. Heating steam for the deaerator is extracted from the steam turbine with a pegging steam supply (14) from the HRSG drum in case the pressure at the steam turbine bleed point becomes too low at off-design conditions.

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Single-Pressure Cycle (continued)
CCPP Operation
The HRSG consists of three heat exchanger sections: the economiser (5), the evaporating loop (4), and the superheater (3). In the economizer, the feedwater is heated to a temperature close to its saturation point. The heated feedwater is evaporated at constant temperature and pressure in the evaporating loop. The water and saturated steam are separated in the drum (6) and the steam is fed to the superheater where it is superheated to the desired live-steam temperature.
Ex
Temperature
ha
us
Evaporator
Ec
Pinch Point
tG as
on
om
ize
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Energy Transfer
Figure 3: Energy/Temperature Diagram for a Single Pressure HRSG
Figure 3 shows the temperature/energy diagram for the single pressure HRSG. The heat exchange in these three different sections is clearly recognizable. It is far removed from an idealized heat exchanger, because the water evaporates at a constant temperature. The area between the gas and water/steam lines illustrates the exergy loss between the exhaust gas and the water/steam cycle. Even with an infinitely large heat transfer surface, this exergy loss can never be equal to zero and the heat exchange process in a boiler can never be ideal. Approach Temperature Two important parameters defining the HRSG are marked on the diagram. The approach temperature is the difference between the saturation temperature in the drum and the water temperature at the economizer outlet. This difference - typically 5 to 12K (9 to 22 F) helps to avoid evaporation in the economizer at off-design conditions.

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Approch Temperature
Su per hea ter
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Pinch Point Temperature
CCPP Operation
The pinch-point temperature is the difference between the evaporator outlet temperature on the water/steam side and on the exhaust gas side. This defines the heating surface and performance of the HRSG. The lower the pinch-point the more heating surface is required and the more steam is generated. Pinch-points are typically between 8 and 15K (14 to 27 F) depending on the economic parameters of the plant. Figure 4 shows the heat balance for the single-pressure cycle where 73.3 kg/s (579400 lb/hr) steam at 205 bar (1,508 psig) and 568 C (1,054 F) is generated. A loss of temperature and pressure in the live-steam line is seen, after which the steam is expanded in a steam turbine with an output of 94.8MW. The resulting gross electrical efficiency of the cycle is 57.7%.
T 60 P 0.2 P 1.013 T 133 M 386.7
M 73.3
M0
P 0.3 M 4.0
P 113.1 T 318
473 MW Natural Gas T 647 M388.7 P 105 T 568 M 73.3
P 100.8 T 565 M 73.3 94.8 MW G M0
178 MW G P 1.013 T 15 X 60%
P 0.045 T 31 M 69.3
P T M X
bar C kg/s rel. Humidity

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Gross Power Output = 272.8 MW Gross Efficiency (LHV) = 57.7%

Figure 4: Heat Balance for a Single Pressure Cycle (Continued next page)

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CCPP Operation
Q 100% Energy in Fuel
0.2% Losses in HRSG
Gas Turbine
37.6%
0.5% Losses Steam Turbine 11.4% Stack 20.1%
0.3% Losses
Condenser 29.9%
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Figure 5: Energy Flow Diagram for the Single Pressure Combined-Cycle Plant
Energetic utilization of the exhaust heat is relatively low, considering that the feedwater temperature is 60 C (140 F), as illustrated by the stack temperature of 133 C (271 F). Fig. 5 shows this in an energy flow diagram, 11.4% of the fuel energy supplied is lost through the stack. Another 29.9% is discharged in the condenser and 1% is equipment losses.

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CCPP Operation
Single-Pressure Cycle with a Preheating Loop in the HRSG
Additional Heat Exchanger
For cycle burning fuels with a high sulphur content, the single-pressure cycle is improved by using an additional heat exchanger at the end of the HRSG. This allows heat recovery for feedwater preheating. The preheating loop must be designed so that temperatures do not drop below the acid dew point. It is normal practice to install an evaporator loop in the HRSG operated at a pressure equivalent to the acid dew point temperature.
14 17 6 LP 8 5 4 18 HP 7 3 Fuel 9 G 2 10 11 G 15 16
1 2 3 4 5 6
Compressor Gas Turbine HP Superheater HP Evaporator HP Economizer LP Evaporator
7 8 9 10 11 12
HP Drum LP Drum Steam Turbine HP Steam Bypass LP Steam Bypass Condenser
13 14 15 16 17 18
Condensate Pump Feedwater Tank/Dearator LP Feedwater Pump HP Feedwater Pump Pegging Steam Line GT Cooler
12
13
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Figure 6: Flow Diagram of a Single Pressure Cycle with LP Preheating Loop for High Sulfur Fuels
Figure 6 shows a solution, in which a low-pressure evaporator (6, 8) generates saturated steam solely for the feedwater tank/deaerator. In this case, because this loop is at a low pressure at the low-temperature end of the HRSG, the power required to drive the additional feedwater pump (15) is quite small.

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CCPP Operation
Single-Pressure Cycle with a Preheating Loop in the HRSG (continued)

The deaerator/feedwater tank could alternatively be integrated into the drum of the preheating loop, which then functions as a feedwater tank for the cycle in providing a water buffer. This simplifies the cycle because additional feedwater pumps and level controls are not required. Exhaust Gas Figure 7 shows the required and available energy in a preheating loop as a function of feedwater temperature and live steam pressure. The required energy is that needed to raise the temperature of the full condensate flow from condenser saturation temperature to the feedwater temperature. The available energy is that in the exhaust gases downstream of the economizer. An eventual stack temperature of 12K (22 F) above the feedwater temperature independent of the live steam pressure is assumed. The higher the feedwater temperature, the more preheating is required. The available energy depends on the live steam pressure for the following reasons. The exhaust gas temperature after the economizer of the HRSG rises as the live steam pressure rises because less steam is produced at higher pressures so less energy is removed from the economizers, leaving more energy available for preheating. A lower feedwater temperature also results in more available energy because the exhaust gases can be cooled to a lower level even though more heating is required. In this case at about 100 C (212 F) the available energy matches required energy.
35
Required
145C 30 135C 125C
Energy (MW)
25
20
Available
15
125C 135C 145C
10 50 55 60 65 70 75 80 85 90 100 105
Live Steam Pressure (bar)
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Figure 7: Effect of Live Steam Pressure and Feedwater Temperature on Available Heat Compared to Required Heat in Preheating Loop

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CCPP Operation

Figure 7 clearly demonstrates that at these feedwater temperatures there is not enough energy in the HRSG to accommodate the necessary preheating of the feedwater. Therefore, some of the preheating is done by other means. If a gas turbine with a lower exhaust gas temperature had been used, more energy would have been available for the preheating loop.
M 7.9 P 1.013 T 148 M 386.7
P 3.1 T 135 M0 M 73.3 M0
P 3.5 T 136
M 7.9
P 113.1 T 318
M 7.1 T 84
T 80
473 MW High Sulfur Natural Gas
T647 M 386.7
P 105 T 568 M 73.3
M0
P 100.8 T 565 M 73.3
92.6 MW
G
P 0.045 T 31 M 73.3
178 MW
G
P 1.013 T 15 X 60%
P T M X

T 31
Gross Power Output = 270.6MW Gross Efficency (LHV) = 57.52%

Figure 8: Heat Balance for a Single Pressure Cycle with LP Preheating Loop
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Figure 8 is an example of a cycle with an evaporator preheating loop and one additional LP condensate preheater. It is fed by a steam turbine extraction of 7.1 kg/s (56300 lb/hr), which preheats the condensate to 80 C (176 F). A lowpressure preheater improves the steam process by extracting the steam at a lower level than a steam turbine extraction to the feedwater tank. The additional preheating loop and preheater increase the plant cost but this investment is balanced by the improvement in efficiency. Even if the fuel contains very high levels of sulphur, the feedwater can be preheated to a sufficiently high temperature with a minor reduction in efficiency.

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CCPP Operation

Figure 9 shows the energy/temperature diagram for the HRSG with a preheating loop where the exhaust gases are cooled by an additional 41K (74 F). Despite these improvements, the cycle efficiency is lower than that of the single-pressure cycle example (57.2% compared to 57.7%), because steam is extracted from the steam turbine to accommodate the higher feedwater temperature, (135 C (275 F) instead of 60 C (140 F)). Utilization of LP Steam At a given feedwater temperature, a single-pressure cycle with a preheating loop, provides better exhaust gas utilization, as shown in Figure 9 compared to the single-pressure cycle. Nevertheless, that utilization is neither energetically nor exergetically optimum. The low-pressure evaporator could, at no great expense, produce more steam than required to preheat the feedwater, if feedwater preheating were done before this evaporator. That excess steam could be converted into mechanical energy if it were admitted into the steam turbine at a suitable point. To do this, the steam turbine must have two steam admissions one for highpressure steam and another for low-pressure steam which constitutes a dualpressure water/steam cycle.
700
600
500
Ex
ha
Su pe
Temperature (C)
us
tG
as
rhe ate
400
r
Evaporator
300
Ec
200
on
om
ize
100
LP Evaporator Preheating Loop
0 0 50 100 150 200 CSXA401795.cdr
Energy Transfer (MW)
Figure 9: Energy/Temperature Diagram for a Single Pressure HRSG with LP Evaporator Preheating Loop

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Dual-Pressure Cycles
CCPP Operation
A dual-pressure cycle for a fuel with a high sulphur content is shown in Figure 10. The LP evaporator loop (6, 8) generates steam for the steam turbine and for feedwater preheating in the feedwater tank (14). There are two stages of condensate preheating with low-pressure preheaters (17), which are fed by extractions from the steam turbine. This makes good thermodynamic sense because the steam, which preheats the feedwater, is of a low quality. As opposed to the single-pressure cycle with a preheating loop, the excess LP steam is expanded in the steam turbine.
14 15 16
LP 8
5 4 18 HP 7 3 High Sulfur Fuel 9 17
2 10
11
1 2 3 4 5 6
Compressor Gas Turbine HP Superheater HP Evaporator HP Economizer LP Evaporator
7 8 9 10 11 12
HP Drum LP Drum Steam Turbine HPSteam Bypass LP Steam Bypass Condenser
13 14 15 16 17 18
Condensate Pump Feedwater Tank / Dearator LP Feedwater Pump HP Feedwater Pump LP Preheater GT Cooler
12
13
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Figure 10: Flow Diagram of a Dual Pressure Cycle for High Sulphur Fuels (Continued next page)

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Dual-Pressure Cycles (continued)
Amount of Preheating Stages
CCPP Operation
Figure 11 shows the effect on steam turbine output and number of preheaters for a range of feedwater temperatures. The higher the required feedwater temperature, the lower the steam turbine output because less energy is available in the HRSG and more steam is required for preheating. Increasing the number of preheating stages, increases the steam turbine output because the steam is used more efficiently. In order to raise the feedwater to the desired temperature, (e.g., 120 C (248 F)), steam must be extracted at a certain level in the steam turbine (say at a pressure corresponding to 130 C (266 F)). If this is done in one stage, all of the steam must be extracted at this pressure. If two stages are used, then a second extraction occurs at a pressure corresponding to say, 100 C (212 F), enabling this steam to expand slightly further in the steam turbine before being extracted, thereby raising the steam turbine output. Although slightly more steam must be extracted at the lower level, performance is negligibly affected. A similar improvement is achieved with further stages of preheating.
100 99
Steam Turbine Output (MW)
98 97 96 95 94 93 92 91 90 60 80 100 Feedwater Temperature (C) 120 140

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1 Feedwater Tank only 2 No. of LP Preheaters: 1 (incl. FWT) 3 No. of LP Preheaters: 2 (incl. FWT)
3 2 1
Figure 11: Effect of Feedwater Temperature and Number of Preheating Stages on Steam Turbine Output of a Dual Pressure Cycle (Continued next page)

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Additional Economizer
CCPP Operation
If a fuel with low-sulphur content is used and the feedwater temperature is reduced, the LP feedwater preheaters of Figure 10 can be replaced by additional economisers in the HRSG. This enables more exhaust gas energy to be utilized, lowering the stack temperature. This is the most common type of dual-pressure cycle (Fig. 12). The first section in the HRSG (7) is a dual-pressure economizer, divided into an LP part for the LP feedwater and a HP part for the first step in heating the HP feedwater. More of the steam generated in the LP evaporator and superheater (6, 5) is available for the dual-admission steam turbine. An extraction is made from the steam turbine for feedwater preheating and deaeration. Pegging steam (18) for offdesign conditions for which the steam turbine extraction pressure is too low is taken from the LP live-steam line.
15 16 7 17 18
6 LP 9 5
4 HP 8 3 Natural Gas
10
11
12
1 2 3 4 5 6 7 8 9 10
Comperssor Gas Turbine HP Supperheater HP Evaporator HP Economizer/LPSuperheater LP Evaporator HP/LP Economize HP Drum LP Drum Steam Turbine
11 12 13 14 15 16 17 18 19
HP Steam Bypass LP Steam Bypass Condenser Condensate Pump Feedwater Tank / Dearator LP Feedwater Pump HP Feedwater Pump Pegging Steam Line GT Cooler
13
14
CSXA401814.cdr
Figure 12: Flow Diagram of a Dual Pressure Cycle for Low Sulphur Fuels (Continued next page)

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Heat Balance
CCPP Operation
Figure 13 shows the heat balance for a dual-pressure cycle burning natural gas with a low-sulphur content and a feedwater temperature of 60 C (140 F). Comparing this with the single-pressure cycle example (Fig. 4) shows how the dualpressure cycle makes better use of the exhaust gas in the HRSG resulting in a higher steam turbine output. The economizers at the end of the HRSG utilize the exhaust gases to a greater extent, lowering the stack temperature to 96 C (205 F) compared to 133 C (272 F) for the single-pressure cycle. The HP part of the HRSG is not affected by the presence of the LP section and HP steam production is the same. Overall steam production is increased due to the 5.4 kg/s (42000 lb/hr) of LP steam. The gross efficiency of the cycle has risen from 57.7% to 58.6% - a considerable increase.
P 1.013 T 96 M 386.7
P 0.2 T 60 M 5.4 M 73.3 M0
P 0.3 M 4.3
P 5.4 T 154
P 5.0 T 313 M 5.4
P 113 T 318
M0
P 4.7 T 311 M 5.4
473 MW Natural Gas T 647 M 386.7 G P 1.013 T 15 X 60% P 105 T 568 M 73.3 P 100.8 T 565 M 73.3 99 MW G
178 MW
M0
P 0.045 T 31 M 74.4
P T M X
bar C kg/s rel. humidity

CSXA401815.cdr
Gross Power Output = 277 MW Gross Efficency (LHV) = 58.6%
Figure 13: Heat Balance for a Dual Pressure Cycle with Low Sulfur Fuel (Continued next page)

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CCPP Operation
Figure 14 shows the heat flow diagram for the dual-pressure cycle. Compared to the single-pressure cycle (Fig. 5), the stack losses are reduced from 11.4% to 8.2% of the total fuel energy input. However, due to the increased LP steam flow, more energy is lost in the condenser 32.1% instead of 29.9%. The portion of the steam turbine output has increased by 0.9%. This shows that the additional absorbed heat in the HRSG is converted with a moderate efficiency of 28% because it is being done at a low temperature level. (Figure 5 shows an energy flow of 50.3% towards the steam turbine where as Figure 14 shows 53.4%. The gain of 0.9% on the steam turbine versus the difference between 53.4% and 50.3% results in an efficiency of 28%.)
0.3% Losses in HRSG
Gas Turbine
37.6%
0.3% Losses
Condenser 32.1%
CSXA401801.cdr
Figure 14: Energy Flow Diagram for the Dual Pressure Combined-Cycle Plant (Continued next page)

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CCPP Operation
700
600
500
HP
Temperature (C)
Su pe rhe
Ex
400
ha
us
tG as
ate r
HP Evaporator
300
200
HP L P Eco Su no pe miz rhe er ate / r

LP Evaporator HP / LP Economizer
100
0 0 50 100 150 200 250 CSXA401796.cdr
Figure 15: Energy/Temperature Diagram for a Dual Pressure HRSG
Figure 15 is the energy/temperature diagram for the dual-pressure HRSG. As it shows, most of the heat exchange takes place in the HP portion of the HRSG. This is directly related to the chosen pressure levels of the cycle.

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Triple-Pressure Cycle
CCPP Operation
If a third pressure level is added to the dual-pressure cycle, a further improvement can be made, mainly by recovering more exergy from the exhaust gas. In the flow diagram shown in Figure 16, separate pumps (20, 21) supply feedwater to a dualpressure economizer (9), one at the HP and the other at the intermediate pressure (IP) level. On leaving the IP economizer, the IP feedwater divides into two parts. One enters a second dual-pressure economizer (7) and the other one is throttled into the LP steam drum (12). The saturated LP steam collecting in the drum is fed directly to the steam turbine. The HP and IP pressure levels follow the pattern of economizer, evaporator, and superheater until the superheated steam generated is fed to the triple-pressure steam turbine. Again, each pressure level has a separate steam turbine bypass (14, 15 and 16).
9 8 19 LP 12 20 21
7 6
IP 11
4 22 HP 10 3
Natural Gas 13 G 2 15 14 17
16
1 Compressor 2 Gas Turbine 3 Dual HP / IP Superheater 4 HP Evaporator 5 HP Economizer / IP Superheater 6 IP Evaporator 7 Dual IP Economizer 8 LP Evaporator 9 LP Economizer 10 HP Drum 11 IP Drum 12 LP Drum
13 14 15 16 17 18 19 20 21 22
Steam Turbine HP Steam Bypass IP Steam Bypass LP Steam Bypass Condenser Condensate Pump Feedwater Tank / Dearator IP Feedwater Pump HP Feedwater Pump GT Cooler
18
CSXA401816.cdr
Figure 16: Flow Diagram of a Triple Pressure Cycle (Continued next page)

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Triple-Pressure Cycle (continued)
Heat Balance
CCPP Operation
Figure 17 shows the heat balance for a triple-pressure cycle with a low-sulphur natural gas fuel and a feedwater temperature of 60 C (140 F). For this example, there is only a slight improvement in output over the dual-pressure cycle, with efficiency improving marginally from 58.6% to 58.7%. The stack temperature is the same. The improvement is due to a slight exergetic gain caused by the LP level reducing the area between the exhaust gas and the water/steam lines (as shown on the energy / temperature diagram, Fig. 18). Compared to the HP flow of 72.5 kg/s (575200 lb/hr), the IP and LP flows are very small only 3.1 kg/s (24600 lb/hr) and 3.0 kg/s (23800 lb/hr) respectively. This limits the potential gain in exergy due to the addition of the IP section. The HP flow is slightly less than that for the dualpressure example because the IP superheater is at a high temperature level, removing energy from the HP section of the HRSG. This has a minor negative effect on output and is part of the reason why the benefit in this triple pressure cycle is so small. A benefit is gained because IP steam is generated in the place of some LP steam.
P 1.013 T 96 M 386.7
P 5.0 T 152
P 0.2 T 60 P 0.3 M 4.2
M 6.1
M 72.5
M0
P 26.3 T 227
P 5.0 T 152 M 3.0 P 4.6 T 150 M 3.0
P 110 T 318
P 25.0 T 543 M 3.1
M0
473 MW Natural Gas T 647 M 386.7 P 105 T 568 M 72.5 P 100.8 T 565 M 72.5 99.7 MW
G
P 0.045 T 31 M 74.4
178 MW
G
P 1.013 T 15 X 60%
M0 M0
P T M X
bar C kg/s rel. humidity
P 24.0 T 540 M 3.1
Gross Power Output = 277.7MW Gross Efficency (LHV) = 58.7 %
CSXA401817.cdr
Figure 17: Heat Balance for a Triple Pressure Cycle (Continued next page)

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ABCD
CCPP Operation
700
600
500
HP
Temperature (C)
Su pe r he
Ex ha
400
us
HP Evaporator
300
tG as
IP Evaporator
ate r
200
HP Economizer / IP Superheater HP / IP Economizer
LP Evaporator
100
HP / IP / LP Economizer
0 0 50 100 150 200 250 CSXA401797.cdr
Figure 18: Energy/Temperature Diagram for a Triple Pressure HRSG (Continued next page)

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ABCD
CCPP Operation
The energy flow diagram (Fig. 19) shows the slight improvement in the steam turbine output over the dual-pressure cycle for the reasons stated above. The stack losses are the same (same stack temperature) but there is a slight decrease in heat load in the condenser that corresponds to the gain in steam turbine output. For gas turbines with lower exhaust gas temperatures, more energy is available for IP steam production because the HP steam production is lower, making this concept more attractive.
0.3% Losses in HRSG
Gas Turbine
37.6%
0.3% Losses
Condenser 32.0%
CSXA401799.cdr
Figure 19: Energy Flow Diagram for the Triple Pressure Combined-Cycle Plant

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ABCD
Reheat Cycles
CCPP Operation
Reducing of From our analysis, the moisture content in the steam turbine exhaust significantly Moisture Content limits further improvements in the performance of the various cycles. By extending the idea of mild reheat, the full reheat cycle is derived in which this moisture content is reduced (Fig. 22) and improvement in the performance is possible. The idea is that (taking the triple-pressure cycle as an example) after the expansion of the HP steam in the steam turbine to IP level, the steam returns to the HRSG and mixes with the steam leaving the IP superheater. This steam is then heated to a temperature similar or equal to the HP live-steam temperature before being admitted to the steam turbine. In a dual-pressure reheat cycle there is no mixing on re-entering the HRSG, the cold reheat goes to an independent reheater section. The reheater takes more exergy out of the HRSG and increases the steam turbine enthalpy drop resulting in a higher steam turbine output. Because the last part of the steam turbine expansion line is moved further to the right on the enthalpy/entropy diagram, there is a reduction in the moisture content (Fig 22). Figure 20 is the flow diagram of the triple-pressure cycle with reheat. The steam turbine has separate HP and IP/LP casings (13, 14) in order to accommodate the extraction of the cold reheat steam. The high-pressure bypass (15), instead of dumping steam into the condenser, dumps it into the cold reheat line to keep the reheat cooled (i.e., the line leaving the HP steam turbine).

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ABCD
Reheat Cycles (continued)
CCPP Operation
9 8 20 22 21
LP 12
7 6 IP 11 5
HP 10
3
Natural Gas
15
13
14
2 16 17
1 2 3 4 5 6 7 8 9 10 11 12
Comperssor Gas Turbine Dual HP Supperheater / Reheater HP Evaporator HP Economizer / IP Supperheater IP Evaporator Dual IP Economizer LP Evaporator Dual LP Economizer HP Drum IP Drum LP Drum
13 14 15 16 17 18 19 20 21 22 23
HP Steam Turbine IP / LP Turbine HPSteam Bypass IP Steam Bypass LP Steam Bypass Condenser Condensate Pump Feedwater Tank / Dearator HP Feedwater Pump IP Feedwater Pump Gas Turbine Cooler
18 19
CSXA401818.cdr
Figure 20: Flow Diagram of a Triple Pressure Reheat Cycle (Continued next page)

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ABCD
Heat Balance
CCPP Operation
The heat balance is shown in Figure 21. The HP live-steam pressure now increased to 120 bar (1725 psig) together with the reheater (which removes energy at the hot end of the HRSG) leads to a reduced HP mass flow of 59.2 kg/s (469700 lb/hr) compared to the triple-pressure cycle. For that reason, the IP steam flow is slightly higher (5.9 kg/s (46800 lb/hr)). However, there is a significant improvement in the cycle performance because, due to the reheat, there is a greater exergy transfer in the hot end of the HRSG. The IP steam is expanded from a high temperature level 65.1 kg/s (516500 lb/hr) from 565 C (1049 F) instead of 75.6 kg/s (599800 lb/hr) (HP and IP steam) from the mix temperature of 354 C (669 F) into the triple-pressure cycle. The resulting gross output is 2.8 MW higher than for the triple-pressure cycle with an efficiency of 59.3 % instead of 58.7%.
P 1.013 T103 M 386.7
P 5.0 T 152
P 0.2 T 60 M 11.3 M 59.2 M0 M 3.5
P 33.7 T 240
P 5.0 T 152 M 5.4
P 126 T 328
P 32.1 T 369 M 5.9
P 4.6 T 150 M 5.4
Natural Gas 178 MW

G
T 647 M 386.7
P 120 T 568 P 30 T 568
P 115.2 T 565 M 59.2
M0 102.5 MW
G
P 1.013 T 15 X 60%
P 28.5 T 565 M 65.1
P 0.045 T 31 M 67
P bar T C M kg/s X rel. Humidity Gross Output = 280.5 MW Gross Efficency (LHV) = 59.3%
Figure 21: Heat Balance for a Triple Pressure Reheat Cycle (Continued next page)
CSXA401819.cdr

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ABCD
CCPP Operation
Decrease of The decrease in the moisture content is illustrated on the enthalpy/Entropy diagram Moisture Content (Fig. 22). The value is 10% compared to 16% in the triple-pressure example. The percentage of the stack losses has increased 0.4% (Fig. 23) because the stack temperature is slightly higher 103 C (217 F). This occurs when the reheater steals energy from the HP section of the HRSG, resulting in less HP steam production and therefore less feedwater heating in the HP economizers. Increases in IP and LP mass flows do not compensate for this and so the stack temperature increases. Combined with the additional steam turbine output, this explains the lower heat loads in the condenser.
T max 568C T
(Temperature)
(1-x) = 10%
ar
0b
ba
5b
ar
(Entropy)
12
HP
30
(1-x) = Moisture Content
IP LP Saturation Line
4 0,0
5b
ar
CSXA401805.cdr
Figure 22: Temperature / Entropy Diagram Showing the Effect of Full Reheat on the Steam Turbine Expansion Line
0.3% Losses in HRSG
Gas Turbine
37.6%
0.3% Losses
Condenser 31.0%
CSXA401800.cdr
Figure 23: Energy Flow Diagram for the Triple Pressure Reheat Combine-Cycle Plant (Continued next page)

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ABCD
Energy / Temperature Diagram
CCPP Operation
The energy/temperature diagram for the triple pressure reheat cycle is shown in Fig. 24. The energy taken out in the HP superheater/reheater and HP evaporator is approximately 138 MW compared to 140 MW for the triple-pressure cycle. This is mainly due to the HP evaporator pressure level difference. However, the energy is transferred at a higher temperature level and because the combined mass flow of the HP superheater/reheater is higher than that of the HP/IP superheater in the triple pressure cycle, this part of the diagram moves closer to the exhaust gas temperature. This results in an exergy gain and therefore a higher steam turbine output.
700
600
HP Su pe
500
rh ea
Temperature (C)
Ex
te r/ h Re
ha
400
us
tG as
ea te r
HP Evaporator
300
IP Evaporatotor HP Economizer / IP Superheater HP / IP Economizer
200
LP Evaporator
100
HP / IP / LP Economizer
0 0 50 100 150 200 250 CSXA401798.cdr
Figure 24: Energy/Temperature Diagram for a Triple Pressure Reheat HRSG
Clearly, there is a performance benefit in a reheat cycle because of the greater expansion in the steam turbine and the improved exergy utilization in the HRSG. Still more is achieved if the live-steam pressure can be raised. State of the art technology can accomplish this task. For dual and triple-pressure cycles, the HP part of the cycle makes the main contribution to the performance. Therefore, this is the area in which major investments should be concentrated in order to improve the reheat cycle performance.

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ABCD
Once through System
CCPP Operation
Figure 25 shows the flow diagram of a cycle that utilizes these factors to achieve a higher efficiency at a lower level of complexity. It is a high-pressure reheat cycle and a dual-pressure cycle because the aim was to improve the exergy exchange in the HP part of the HRSG. A once-through HRSG HP section (2, 4) is chosen to accommodate the higher HP steam pressure. Unlike the conventional drum system, here there is no drum and the economiser, evaporator and superheater form a continuous HRSG section. The separator (5) ensures safe operation and control of the HRSG. For example, it prevents water from entering the superheater, and provides blow down for the HP section. Under normal operating conditions, the separator is dry. The same equipment is used in conventional plants with oncethrough boilers. The LP part of the HRSG is of the drum type design. The increased HP pressure improves the exergy transfer in the HP section, although this improvement is partly reduced because there is no IP section that is omitted in order to reduce the complexity of the cycle. For steam turbine bypass operation the reheater is run dry and all HP steam is dumped into the condenser. The tube material is selected accordindly.

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ABCD
CCPP Operation
10 7 8 LP 9
3 6
13
4 5
Natural Gas 11 12 14
G
G
15
1 16
1 2 3 4 5 6 7 8 9
Gas Turbine HP Supperheater / Reheater HP Economizer HP Evaporator Water Separator LP Supperheater Recirculation Pump LP Evaporator LP Drum
10 11 12 13 14 15 16 17 18
LP Economizer HP Steam Turbine IP / LP Steam Turbine HP Feedwater Pump HP Steam Bypass LP Steam Bypass Condenser Condensate Pump GT Cooler
17
CSXA401820.cdr
Figure 25: Flow Diagram of a High Pressure Rehaet Cycle with a HP Obe Through and a Drum Type LP Section
The cycle has no feedwater tank, so deaeration occurs in the condenser and a recirculation loop in the LP economizer of the HRSG raises the temperature of the incoming feedwater. The condensate pumps (17) must be designed to bring the condensate to the LP drum, which also fulfils the function of LP feedwater pumps. The HP feedwater pumps (13) take suction from the LP drum.

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ABCD
Heat Balance
CCPP Operation
The heat balance is shown in Figure 1-46. As expected, performance is further improved. The gross output is 2.4 MW above that of the triple-pressure reheat cycle and efficiency increases from 59.3% to 59.8% - a considerable improvement. Part of this benefit comes because a once-through HRSG is designed with an approach point temperature of zero but the same pinch-point (12 K (22 F)) is used as in the other examples. However, due to the increased pressure of the HP system, power consumed in the feedwater pumps is higher, slightly reducing the gain in the net power output. The example is offered with a fuel that has no sulphur content so the feedwater temperature has been reduced to optimize the energy in the cold end of the HRSG. In such a cycle, the feedwater temperature affects the HRSG surface but not the performance. This is valid as long as there is sufficient energy available in the exhaust gas to preheat the incoming condensate. Gross efficiencies approaching 60% are the current state of the art for combined-cycle power plants with this concept under the given ISO conditions.
P 1.013 T 80 M 386.7
T 45 M 79.1 M 8.0
P 7.4 T 167
M0
P 7.0 T 322 M9.5
P 42.8 T 568 M 61.6 473 MW Natural Gas
P 40.0 T 371 M 61.6
P 38.0 T 565 M 61.6
P 6.6 M 0 T 320 M 9.5 104.8 MW

G
178 MW
G
P 160 T 647 M 386.7 T 568 M 61.6
P 153.6 T 565 M 61.6
M0 P 0.045 T 31 M 71.1
P 1.103 T 15 X 60
P T M X
CSXA401821.cdr
Total Power (Gross) = 282.9 MW Gross Efficency (LHV) = 59.8%

Figure 26: Heat Balance for a dUal Pressure Reheat Cycle with Once Through HRSG

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ABCD
CCPP Operation
Cycles with Supplementary Firing
Purpose
Supplementary firing increases the plant output by installing duct burners in the HRSG inlet duct. This adds energy to the cycle by increasing the exhaust gas temperature often at the expense of efficiency. Supplementary firing is appropriate for HRSGs because there is usually sufficient oxygen content in the exhaust gas to act as combustion air. In an open cycle gas turbine, with a single stage of combustion, only 30-50% of the oxygen contained in the air is used for combustion. Earlier combined-cycle installations generally had supplementary firing. This is not the case today due to progress in the development of the gas turbine. As gasturbine inlet temperatures and hence exhaust gas temperatures increase, the importance of supplementary firing diminishes for two reasons. First, because the temperature window between the gas turbine exhaust and the duct burner exhaust decreases so the added benefit of supplementary firing decreases. Second, optimum values can be given to the water/steam cycle parameters with the gas turbine alone. Since current levels of efficiency are set by reheat cycles, the efficiencies achieved in cycles with supplementary firing lead to a high cost of electricity. Nevertheless, increased operating and fuel flexibility of the combined-cycle with supplementary firing may be an advantage in special cases, particularly in installations used for cogeneration of heat and power where this arrangement makes it possible to control the electrical and thermal outputs separately.

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ABCD
CCPP Operation
Cycles with Supplementary Firing (continued)

Energy / Temperature Diagram Figure 27 shows energy/temperature diagrams for a single-pressure HRSG with constant live-steam conditions and inlet exhaust gas temperatures of 647 C, (1,197 F), 750 C, (1,382 F) and 1,000 C, (1,832 F), the latter two, after supplementary firing. At 647 C the temperatures of gas and water in the economizer are convergent, with the minimum difference in temperature on the evaporator end, typical for an HRSG without supplementary firing. At 1,000 C (1,832 F), on the other hand, the minimum difference in temperature is at the inlet to the economizer on the waterside. This pattern corresponds more to that of a conventional steam generator.
700 600 500 400 300 200 100 0 0 800 10 20 30 40 50 60 70 80 90 100
Temperature (C)
Figure A
Energy Transfer (%)

Temperature (C)
700 600 500 400 300 200 100 0 0 1100 1000 10 20 30 40 50 60 70 80 90 100
Figure B
Energy Transfer (%)
Temperature (C)
900 800 700 600 500 400 300 200 100 0 0 10 20 30 40 50 60 70 80 90 100
Figure C
Energy Transfer (%)
CSXA401806.cdr
Figure 27: Energy/Temperature Diagram for 647 C (A), 750 C (B) and 1000 C (C) Exhaust Gas Temperature Entering the HRSG
A temperature of 750 C (1,382 F) supplementary firing gives the best exergetic utilization of the exhaust gas with a constant difference in temperature along the entire economizer. The single pressure cycle here is at an optimum with the exhaust gas cooled down to a temperature close to the feedwater temperature. There is no exergy or energy available for additional pressure levels.

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ABCD
CCPP Operation

Figure 28 shows how relative power output and efficiency depend on the temperature after supplementary firing for a single and a dual-pressure cycle. The reference point at 647 C (1,197 F) is the single-pressure cycle. The reference point at 647 C (1,197 F) is the single-pressure cycle without supplementary firing. Above 750 C (1,382 F) there is no longer any performance benefit in the dual-pressure cycle. Calculations assume the use of natural gas fuel. When burning oil, the curve paths for the single-pressure system are not significantly changed, but there is less difference between the single and dual-pressure systems. Triple-pressure and triplepressure reheat cycles follow the same pattern, starting out with a larger difference without supplementary firing and ending at the same point at 750 C (1382 F).
Relative Gross Plant Efficiency and relative Gross Output (%)
130 125 Dual Pressure Single Pressure 120 115 Relative Gross Output
110
105 100 Relative Gross Efficiency 95
90 650 700 750 800 850 900 950 1000
Exhaust Gas Temperature (C)

CSXA401807.cdr
Figure 28: Effect of Temperature after Supplementary Firing on Power Output and Efficiency Relative to that of a Single Pressure Cycle
For installations with supplementary firing that are frequently operated at part loads, it could make economic sense to select a cycle with more pressure levels or even reheat. At part loads or when the supplementary firing is switched off, the exhaust gas temperature at the outlet of the HP section rises and an LP section enables this exhaust gas energy to be used.

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ABCD
CCPP Operation

Heat Balance Figure 29 shows the heat balance of a typical combined-cycle plant with supplementary firing to 750 C, (1,382 F) with natural gas and a feedwater temperature of 60 C (140 F). The basic arrangement for this installation is the same as that for the single-pressure system in Figure 4.
P 1.013 T 71 M 387.7
T 60 P 0.2
M 96.5
P 0.3 M 5.2
P 113.1 T 318
524 MW Natural Gas 51.0 MW
T 750
P 105 T 565 M 96.5
P 100.8 T 565 M 96.5
125.5 MW G
T 647 M 386.7 178 MW G P 1.013 T 15 X 60%
M0 P 0.045 T 31 M 91.3
P T M X
CSXA401810.cdr
Gross Power Output = 303.5 MW Gross Efficiency (LHV) = 57.9%

Figure 29: Heat Balance for a Single Pressure Cycle with Supplementary Firing
Supplementary firing increases the steam turbine output by 24.3 MW compared to the cycle without supplementary firing. The efficiency rises slightly from 57.7% to 57.9% because the increased steam production also results in increased mass flows through the economizers removing more energy from the exhaust gas, thus lowering the stack temperature. Generally, for cycles with more pressure levels supplementary firing has a negative effect on the efficiency because without supplementary firing these cycle already make maximum use of the exhaust gas energy.

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ABCD
CCPP Operation
Summary of Cycle Performance
To give an overview of all the cycles discussed in this section, the performance data for the examples in this section are summarized in Table 1. The auxiliary power consumption for each case ant the resulting net output and efficiency are also given, which are important for comparing the cycles in real terms.
Single Pressure
Gas Turbine Fuel Input (LHV) Duct Burner Fuel Input (LHV) Total Fuel Input (LHV) Gas Turbine Output Steam Turbine Output Gross Output Gross Efficiency (LHV) Auxiliary Consumption Net Output Net Efficiency (LHV) Net Heat Rate (LHV) Net Heat Rate (LHV)
MW MW MW MW MW MW % MW MW % kJ/kWh Btu/kWh
473 0 473 178 94.8 272.8 57.5 4.1 268.7 56.8 6.337 6.006
473 0 473 178 99.0 277 58.6 4.5 272.5 57.6 6.249 5.923
473 0 473 178 99.7 277.7 58.7 4.5 273.2 57.8 6.233 5.908
473 0 473 178 102.5 280.5 59.3 4.6 275.9 58.3 6.172 5.850
473 0 473 178 104.9 282.9 59.8 5.2 277.7 58.7 6.132 5.812
Table 1: Performance Comparison for Different Cycle Concepts (Natural Gas Fuel with Low Sulphur Content)
The above examples illustrate how the net efficiency can rise from 56.8% to 58.7% and the output from 268.7 MW to 277.7 MW by changing the concept of the water/steam cycle. Adding supplementary firing can increase this output further, but for cycles with several pressure levels at the expense of the efficiency.

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Single Pressure Supplementary Firing 473 51 524 178 125.5 303.5 57.9 5.0 298.5 57.0 6.320 5.990
Triple Pressure
Triple Pressure Reheat
Dual Pressure
Dual Pressure Reheat
ABCD
CCPP Operation
Exercises Combined Cycle Power Plant Concepts

HRSG Energy / Temperature Diagram
Exercise Task Draw an energy/temperature diagram for your combined cycle power plants HRSG and do the following: Define (and calculate) the thermal energy exchanged in each boiler section. Color each specific heat exchanger section in your cross-sectional boiler drawing. Compare and discuss the thermal energy calculations with your colored heat exchanger sections. Discuss the effect a gas turbine exhaust gas temperature drop of 50 C (GT remains at base load) would have on your boiler performance. HRSG process data table HRSG cross section drawing with tubing details Guarantee Heat balance Group work with max. 4 trainees per group 30 minutes Group presentation in front of class
Exercise Aids
Group, Time Frame, Presentation

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ABCD
Energy Flow Diagram
Exercise Task
CCPP Operation
Calculate and draw an energy flow diagram for your combined cycle plant including the energy flow internally in the gas turbine (energy consumption of compressor) to understand: Energy input GT internal energy use Power output (GT; ST) Energy losses Process flow sheet Water/Steam Cycle Guarantee Heat balance Group work with max. 4 trainees per group 20 minutes Group presentation in front of class
Exercise Aids
Group, Time Frame, Presentation

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ABCD
Summary
Objectives Review
CCPP Operation
Carefully review the objectives stated on page 6 of this lesson together with the Test Questions for Verification of Learning Progress. Note that this lesson is not complete without the system specific and overall plant Operation & Maintenance Documentation.

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Combined Cycle Power Plant Operation

Combined Cycle Power Plant Concepts Training Lesson

ALSTOM (Switzerland) Ltd

Combined Cycle Power Plant Concepts

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Combined Cycle Power Plant Concepts

Power Plant Training Center

Combined Cycle Power Plant Concepts

Power Plant Training Center

Combined Cycle Power Plant Concepts

Power Plant Training Center

Combined Cycle Power Plant Concepts

Power Plant Training Center

Combined Cycle Power Plant Concepts

The Combined Cycle Process

Figure 1: Energy/Temperature Diagram for an Idealized Heat Exchanger

Power Plant Training Center

Combined Cycle Power Plant Concepts

The Combined Cycle Process (continued)

Basic Combined-Cycle Concepts

Power Plant Training Center

Combined Cycle Power Plant Concepts

Air Compressor Turbine (Gas) Superheater Evaporator Economizer

Drum Steam Turbine Steam Turbine Bypass Condenser Condensate Pump

Figure 2: Flow Diagram of a Single Pressure Cycle

Power Plant Training Center

Combined Cycle Power Plant Concepts

Figure 3: Energy/Temperature Diagram for a Single Pressure HRSG

Power Plant Training Center

Su per hea ter

Combined Cycle Power Plant Concepts

T 60 P 0.2 P 1.013 T 133 M 386.7

473 MW Natural Gas T 647 M388.7 P 105 T 568 M 73.3

P 100.8 T 565 M 73.3 94.8 MW G M0

178 MW G P 1.013 T 15 X 60%

bar C kg/s rel. Humidity

Gross Power Output = 272.8 MW Gross Efficiency (LHV) = 57.7%

Power Plant Training Center

Combined Cycle Power Plant Concepts

Q 100% Energy in Fuel

0.2% Losses in HRSG

0.5% Losses Steam Turbine 11.4% Stack 20.1%

Power Plant Training Center

Combined Cycle Power Plant Concepts

Single-Pressure Cycle with a Preheating Loop in the HRSG

Additional Heat Exchanger

Compressor Gas Turbine HP Superheater HP Evaporator HP Economizer LP Evaporator

HP Drum LP Drum Steam Turbine HP Steam Bypass LP Steam Bypass Condenser

Power Plant Training Center

Combined Cycle Power Plant Concepts

Single-Pressure Cycle with a Preheating Loop in the HRSG (continued)

125C 135C 145C

Live Steam Pressure (bar)

Power Plant Training Center

Combined Cycle Power Plant Concepts

Single-Pressure Cycle with a Preheating Loop in the HRSG (continued)

M 7.9 P 1.013 T 148 M 386.7

P 3.1 T 135 M0 M 73.3 M0

473 MW High Sulfur Natural Gas

P 105 T 568 M 73.3

P 100.8 T 565 M 73.3

bar C kg/s rel. Humidity

Gross Power Output = 270.6MW Gross Efficency (LHV) = 57.52%