C10 ST (CC)

HIPT
10. Steam Turbines for Combined Cycle 10. Steam Turbines for Combined Cycle
Power Plants Power Plants Power Plants Power Plants
207D-17 Steam Turbine
Combined Cycle Power Plants 10. Steam Turbines for CCPPs 1 / 78
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Steam Turbines for Combined Cycle 2 1
Factors Affecting Cycle Performance 38 3
Type of Steam Turbines 22 2
Part Load Operation of Steam Turbines 73 5
LP Exhaust Hood 62 4
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Rankine Cycle
The thermodynamic cycle for the steam turbine is the
Rankine cycle
Rankine cycle.
In the steam cycle, water is first pumped to high pressure.
It is then heated to the boiling temperature corresponding

to the pressure, boiled (heated from liquid to vapor), and
then superheated (heated to a temperature above that of
boiling).
boiling).
A multistage turbine expands the pressurized steam to
lower pressure and the steam is then exhausted either to
a condenser at vacuum conditions or into an intermediate
T

a condenser at vacuum conditions or into an intermediate
temperature steam distribution system that delivers the
steam to the industrial or commercial application.
The condensate from the condenser or from the steam

utilization system returns to the feedwater pump for
continuation of the cycle.


s
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Combined Cycle
Fuel
Combustor
G
5
6
Steam Turbine
2 3
G G
H
R
S
G
Compressor Turbine
Air
Exhaust gas
1
4
7
9
Condenser
8
Pump
[ A simple schematic diagram of a combined cycle system ]
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Power Output Ratio
T
Topping Cycle
1
pp g y
(Brayton Cycle)
2
GT : ST = 2 : 1
Bottoming Cycle
(Rankine Cycle)
GT : ST 2 : 1
s
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Combined Cycle
Three Pressure
Reheat Cycle
Fuel Fuel
G
Heat Recovery
Steam Generator
Air
Gas Turbine
IP Steam
LP
Cold Reheat
Hot Reheat
Steam
Main
St
G
Steam
Steam
Steam
Steam HP IP/LP
Condenser
Steam Turbine
Condensate Pump
Water
Fuel
Air
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Typical STs for CCPPs
D 11 (GE)
1,800 psig/1,050F/1,050F
D-11 (GE)
SV/CV
CRV
SV/CV
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D 11 (GE)
207FA 209FA
D-11 (GE)
207FA 209FA
Steam conditions, psig/F/F
(psig/C/C)
1800/1050/1050
(1800/566/566)
P t l d ti d Slidi ti ith f ll d i i Part load operating mode Sliding pressure operation with full arc admission
Rating, MW 180 283
Number of casings 2 2
Number of stages
HP 11 10
IP 7 8
LP (per flow) 5 5
rpm 3600 3000
30
LSBs, inch
30
33.5
40
33.5
42
207FA: means that two 7FA gas turbines are applied in a two on one configuration with a single
207FA: means that two 7FA gas turbines are applied in a two-on-one configuration with a single
steam turbine
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D 11 (GE)
1) Opposed flow HP/IP section
D-11 (GE)
Even temperature gradient from the center of the casing to the ends.
Minimum thrust force.
HP/IP section utilizes single shell.
2) Steam path design
HP/IP stages are designed by low reaction design theory.
The HP section was designed to accommodate up to 45% additional throttle mass flow for
supplementary firing.
3) LP turbine
Same as the LP turbine used for Korean standard 500 MW class.
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GEA18 86 (J /2011)
GEA18786 (June/2011)
109D-14 ST
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KN S T bi (Si )
SIEMENS up to 700 MW
for steam power plants
KN Steam Turbine (Siemens)
X-over pipe
Double flow LP
p p
and CCPP
Synchronous self-shifting
clutch (not on picture)
Expansion joint
T i
clutch (not on picture)
Turning gear
C bi d HP/IP f
Combined HP/IP for
full arc admission
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Steam Turbine
Steam turbines are one of the most versatile and oldest prime
mover technologies still in use.
Power generation using steam turbines has being used for about
100 years due to higher efficiencies and lower costs.
The HRSGs are used to convert the heat energy contained in the The HRSGs are used to convert the heat energy contained in the
gas turbine exhaust gas to steam.
This steam is sent to the steam turbine and converted to
mechanical energy to turn the generator mechanical energy to turn the generator.
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Si l Sh f [GE]
Steam Turbine Arrangement
Single-Shaft [GE]
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Si l Sh f [Si ]
Single-Shaft [Siemens]
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Si l Sh f
Single-shaft with generator between gas turbine and steam turbine enables installation of a clutch between
steam turbine and generator.
Single-Shaft
One problem of a Jaw clutch, which was used previously, is that it can only be engaged when the gas turbine
is at rest. This means that in the event of a failed gas turbine start, the operator must wait until the gas
turbine is stationary before engaging the jaw clutch to re-start.
Currently, SSS(Synchronous Self-Shifting) clutch has been employed popularly. The SSS clutch engages in
that moment when the steam turbine speed tries to overrun the rigidly coupled gas turbine generator and
disengages if the torque transmitted from the steam turbine to the generator becomes zero.
The clutch allows startup and operation of gas turbine without driving the steam turbine.
This results in a lower starting power and eliminates certain safety measures for the steam turbine, such as g y
cooling steam or sealing steam.
The clutch also provides design opportunities for accommodating axial thermal expansion.
However, the clutch is an additional component with a potential impact on availability. Additionally, the
generator located at the end of the line of shafting has advantages during generator overhaul.
Single-shaft units without a clutch definitely need auxiliary steam supply to cool the steam turbine during
Single shaft units without a clutch definitely need auxiliary steam supply to cool the steam turbine during
startup. This is not necessary in units with a clutch.
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M l i Sh f [207FA GE]
Multi-Shaft [207FA GE]
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Single Shaft Multiple Shaft
Less generator required One large ST instead of 2 smaller STs
Components
Less generator required
One compact lube oil system
One large ST instead of 2 smaller STs
Less auxiliaries (pumps etc) required
Civil Smaller plant area Higher flexibility in plant layout
Costs Lower specific cost of plant
Performance Same level in larger plants
Steam turbine has higher efficiency because
of larger steam volume of larger steam volume
Operational
Flexibility
Suitable for daily start and stop (DSS)
operation
Suitable for base load operation
Availability Higher (less complexity)
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Enhancement of Main Steam Conditions
Traditional Modern
EGT C 450 550 550 650 EGT, C
(F)
450-550
(842-1022)
550-650
(1022-1202)
Steam Temperature, C
(F)
420-520
(788 968)
520-600
(968 1112) (F) (788-968) (968-1112)
Number of Steam Pressure Level 1 or 2 2 or 3
Steam Pressure, bar 30-100 100-170
(psig) (420-1430) (1430-2460)
Reheat Steam Cycle no yes
Number of Gas Turbines per Steam Turbine 1 to 5 1 to 2
As the exhaust temperatures of gas turbines are over 600C, there is sufficient spare heat in the flue
gases that can be used to reheat the steam gases that can be used to reheat the steam.
The output of the steam turbines are higher and HRSG heat rate is reduced by the employment of
reheating cycle.
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Main Steam Conditions
HRSG 1 50%
( )
HRSG LSB
(:
)
HRSG
LP LP (: LP 3
. HP IP
)
500 MW LP 125 MW

EGT 600 ,
3 (3-pressure, reheat cycle)
HRSG
HRSG, ,
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Main Steam Conditions
,
( )
2-on-1 configuration
(thermal flexibility)
100~170 bar 160~300 bar
LSB LSB
,

3 30% (
60% )
LP LSB 15% ( LSB
10% )
/
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Summary for Main Steam Conditions
Higher main steam temperatures require more expensive alloys in the HRSG, steam piping, and steam
The followings must be considered when the main steam parameters are increased
g p q p y p p g
turbine. The gain in output must, therefore, justify this additional investment.
Higher main steam pressures cause wall thickness to increase, which, in general, reduces thermal
flexibility and increases cost. Once-through HRSGs will be installed more frequently to avoid the negative y g q y g
impact on thermal flexibility of the higher main steam pressures.
High main steam pressure in combination with reheat steam turbine reduces the main steam volume,
which may result in a reduction in the efficiency of the high-pressure steam turbine due to shorter blades. y y g p
However, this problem can be overcome by employment of 2 on 1 configuration.
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Steam Turbines for Combined Cycle 1
Factors Affecting Cycle Performance 3
Type of Steam Turbines 2
Part Load Operation of Steam Turbines 5
LP Exhaust Hood 4
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Reheat Turbines
High pressure steam
Power
output
To condenser
Cold
reheat
Hot
reheat
To condenser
HP LP IP
Reheat turbines are special condensing units applied to large, high pressure power plants.
To condenser
reheat reheat
To condenser
Reheat is becoming common for the large combined cycle power plants, where inlet pressures and
temperatures are rising to those commonly found in traditional fossil power plants.
In the reheat turbine all the steam expanded through the high pressure turbine is removed from the unit and In the reheat turbine, all the steam expanded through the high pressure turbine is removed from the unit, and
taken as cold-reheat to the reheater of a HRSG.
Usually, cold-reheat steam is reheated back to the original inlet steam temperature, and admitted back into
the IP turbine as hot reheat steam at the same temperature as the inlet although at a lower pressure
the IP turbine as hot-reheat steam, at the same temperature as the inlet although at a lower pressure.
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Reheat Turbines
Reheat turbines maintain acceptable levels of wetness in the LP
turbine, while the increased length of steam expansion line results in
increased power and efficiency although it requires a significant increased power and efficiency although it requires a significant
increase in equipment cost.
Multi-cylinder configurations are suitable for reheat turbine, because
of the large diameters of the piping takeoffs and inlets. g p p g
It requires reheat stop valve and intercept valve to control the unit
during startup and transients.
[ GE D11 reheat steam turbine ]
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Condensing Steam Turbines
The primary type of turbine used for central power generation is
the condensing turbine.
Condensing turbines exhaust steam directly to condensers that
High pressure steam
Condensing turbines exhaust steam directly to condensers that
maintain vacuum condition, that is significantly below
atmospheric pressure.
An arrays of tubes, cooled by cooling water, condensates the
Power output
steam into water and creates condenser vacuum.
As a result of condensation, the volume of the exhaust steam
reduces by several order of magnitude, and since the process
t k l i l d l t d t t i takes place in a closed vessel, a steady-state vacuum is
created and maintained, which keeps the process and cycle
going.
The term condensing refers to the condensing system that is
Condenser
The term condensing refers to the condensing system that is
attached to the unit and acts to condense the exhaust steam.
The condensing turbines have large exhaust areas since the
steam is expanded to low pressures, extracting as much of the p p g
useful energy as reasonably possible to being exhausted.
Under the vacuum pressure, specific volume of steam is very
high, thus longer blades are required at the last stage before
t i t th d C d i
steam goes into the condensers. Condensing steam
turbine (65 MW)
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An exhaust hood or diffuser is provided downstream last stage blade to minimize exhaust loss by reduction
of the steam velocity.
The steam exhausted into condenser has a quality of near 90% and this is the main cause of the water The steam exhausted into condenser has a quality of near 90%, and this is the main cause of the water
droplet erosion of blades.
The large power plants for electricity generation are this type of turbine because of maximum power output
d l t i l ti ffi i and electrical generation efficiency.
The power output of condensing turbines is sensitive to ambient conditions.
C d i t bi d f ll l fi d il d fi d t t bi ll l t t bi Condensing turbines are used for all coal-fired, oil- and gas-fired steam turbines, all nuclear steam turbines,
and most of combined cycle plants.
The size range of the condensing turbines is from as small as 5 MW, up to 1500 MW units employed in
power utility.
For combined cycle plants, the maximum size will be 200~250 MW.
Typical condensing pressure are 0.75 in.Hga for the coldest condensing systems, up to a maximum of 10
in.Hga for air-cooled condensing system.
As a small amount of air leaks into the system when it is below atmospheric pressure, a relatively small
pump removes non-condensable gases from the condenser.
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H B l f C d i T bi
Single Pressure
Supplementary Firing
Heat Balance for a Condensing Turbine
Condensing Turbine
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Back Pressure Steam Turbines
The term back-pressure refers to turbines that exhaust steam
at atmospheric pressures and above.
High pressure
steam
Power
At these pressure, the specific volume of the steam is relatively
small, and consequently blade height and exhaust piping are
also relatively small.
Power
output
also relatively small.
Backpressure steam turbines do not have condenser, and this
is the reason why the backpressure turbine is called as non-
Low pressure
steam to process
condensing turbine.
Backpressure turbine exhausts its entire steam flow to the
i d t i l t industrial process steam.
Usually, the steam sent for process is not much above
saturation temperature saturation temperature.
The specific application establishes the discharge pressure,
and 50 150 and 250 psig are the most typical pressure levels
Backpressure steam
and 50, 150, and 250 psig are the most typical pressure levels.
Backpressure steam
turbine (28 MW)
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District heating system most often use the lower pressures, and industrial processes use the higher
pressures pressures.
Industrial processes often include further expansion for mechanical drives, using small steam turbines for
driving heavy equipment that runs continuously for long periods driving heavy equipment that runs continuously for long periods.
Power generation capability reduces significantly when steam is used at appreciable pressure rather than
being e panded to ac m in a condenser being expanded to vacuum in a condenser.
Discharging steam into a steam distribution system at 150 psig can sacrifice slightly more than half the
th t ld b t d h th i l t t diti 750 i d 800 F t i l f ll power that could be generated when the inlet steam conditions are 750 psig and 800F, typical of small
steam turbine systems.
The exhaust pressure is controlled by a regulating valve to suit the needs of the process steam pressure.
These are commonly found at facilities where large amount of low pressure process steam is needed.
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C d i B k T bi
Condensing vs. Backpressure Turbine
Condensing steam
turbine (65 MW) turbine (65 MW)
Backpressure steam
turbine (28 MW)
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H B l f B k T bi
Single Pressure
Heat Balance for a Backpressure Turbine
pp y g
Backpressure Turbine
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Extraction Turbines
The extraction turbine has opening(s) in its
casing for extraction of a portion of the steam at
some intermediate pressure before condensing some intermediate pressure before condensing
the remaining steam.
The term extraction means that the removing
steam from an intermediate stage of the turbine steam from an intermediate stage of the turbine
during the expansion of the steam through a
turbine,
In most power plants some steam is extracted In most power plants, some steam is extracted
from the turbine expansion process and supplied
to heat exchangers for feedwater heating.
Thi t f t ti i i d This type of extraction varies in pressure and
flow as a function of load.
This variation is acceptable and therefore no
ff t i d t l t th effect is made to regulate the pressure.
This type of extraction called uncontrolled, or
nonautomatic extraction.
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Extraction Turbines
The steam extraction pressure may or may not be
automatically regulated.
High pressure steam
Turbines supplying steam for process applications typically
must supply steam at a constant pressure.
Since the steam pressure varies with load unless
Power output
controlled, valve is included in the turbine steam expansion
path to control the pressure.
The extraction turbine has opening(s) in its casing for
extraction of a portion of the steam at some intermediate
pressure before condensing the remaining steam.
Condenser
Medium/low pressure steam
to process
This valve restricts the flow to the downstream stages as required to maintain the pressure of the
extraction stage.
This type of turbine is called a controlled or automatic extraction turbine.
If several controlled extraction points are required in any one turbine, multiple internal control valves are
provided.
Regulated extraction permits more steam to flow through the turbine to generate additional electricity
g p g g y
during periods of low thermal demand by the CHP system.
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Extraction Turbines
Feedwater heating deaeration extraction from LP turbine is generally used for cycles where the gas turbine
[ Layout with possible extraction D-11 (GE) ]
fuel has relatively high sulfur content.
Occasionally, a concern with high sulfur gas turbine fuels is acid condensation on low temperature heat
transfer surfaces. In these cases, an LP turbine extraction may be used to heat feedwater above the acid
de point prior to feed ater s ppl to the HRSG economi er
dew point prior to feedwater supply to the HRSG economizer.
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Extraction Turbines
[Packaged cogeneration unit with multiple inlet control valves and automatic extraction ]
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Admission Turbines
In large, often complex, industrial plants, additional steam may be admitted (flows into the casing and
increases the flow in the steam path) to the steam turbine.
Often this happens when using multiple boilers at different pressure, because of their historical existence.
pp g p p ,
These steam turbines are referred to as admission turbines.
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Admission Turbines
[ 207D 17 Steam Turbine (GE) ] [ 207D-17 Steam Turbine (GE) ]
[ KN Steam Turbine (Siemens) ]
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LP Exhaust Hood 4
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1_Superheating
T
3
'
For a better understanding of various steam cycle
parameters, a thorough investigation of the ideal
Carnot cycle is very helpful.
2
'
3
3
y y p
It is not mechanically practical to partially condense
steam to a particular quality from state 4 to state 1
'
and
then compress the wet steam from state 1
'
to state 2
'
.
4
'
1
'
1
2
4
p
For these reasons, actual steam cycles are based on a
modified version of the Carnot cycle called the Rankine
cycle.
s
4 1 1
a
b c
4 cycle.
Cycle T-s Diagram Remarks
Vapor Carnot cycle 1
'
-2
'
-3-4 q
th
= 1 T
4
/T
3
= 1 T
L
/T
H
Rankine cycle without Nuclear power steam cycle Rankine cycle without
superheating
1-2-3-4
Nuclear power steam cycle
Cycle efficiency is lower than Carnot cycle
Rankine cycle with
superheating
1-2-3
'
-4
'
Fossil power steam cycle
Cycle efficiency increase by application of
superheating
y y y pp
superheating
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1_Superheating
T
Equivalent
Carnot Cycle
Equivalent Cycle Hot
Temperature
T
3
Equivalent Cycle Hot
Temperature
3
3
2
2
s
1 4
s
1 4
[Ideal Rankine Cycle for a Typical Nuclear Power] [Ideal Rankine Cycle for a Typical Fossil Power]
The higher the equivalent cycle hot temperature, the greater the cycle efficiency.
The average temperature where heat is supplied in the boiler can be increased by superheating the
steam.
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1_Superheating
The overall efficiency is increased by
superheating the steam. This is because the
mean temperature where heat is added
T
4
p
increases, while the condenser temperature
remains constant.
Increasing the steam temperature not only
energy
3
Increasing the steam temperature not only
improves the cycle efficiency, but also reduces
the moisture content at the turbine exhaust end
and thus increases the turbine internal
efficiency
energy
added
2
5
5'
efficiency.
The turbine work out is also increased by
superheating the steam without increasing the
s
energy
lost
1
5
boiler pressure.
When the superheating the steam is employed
in the cycle the important thing is that the in the cycle, the important thing is that the
quality of the steam at the turbine exhaust is
higher than 90%.
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2_Condenser Pressure
Except for choked turbine exhaust conditions, the lower the turbine exhaust pressure, the higher the
cycle efficiency.
60%
100
1
HR
HR
KW
A
+
A
= A
70%
Throttle Flow Rate
k
W
h
100
AKW = change of generator kW
output, %.
AHR = change of heat rate, %
100%
90%
80%
a
t

r
a
t
e
,

B
t
u
/
k
T
3
3.5
4.5
100%
Condenser
Pressure
(in Hga)
T
u
r
b
i
n
e

h
e
a
p
2
p
4
2.5
(in.Hga)
T
2
'
p
4
1
'
1
2
b
4
4
'
Turbine output, kW
s a
b
a
'
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195
2 F-40.0"LSB
D-11 steam turbine for GE 207FA,
1800 psia / 1050F / 1050F
W
195
190
2 F-33.5"LSB
2 F-30.0"LSB
O
u
t
p
u
t
,

M
W
190
a
m

T
u
r
b
i
n
e

185
S
t
e
a
180
Condenser Pressure, in.Hga
0.5 1.5 1.0 2.5 2.0 3.5 3.0 0.0
175
4.0
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When the ambient temperature is low, gas turbine output and HRSG steam production are increased above
plant rating point.
Condenser (e ha st) press re directl infl enced b ambient air or cooling ater temperat re Condenser (exhaust) pressure directly influenced by ambient air or cooling water temperature.
Condenser pressure is expected to be lowest at low ambient air / cooling water temperature, and exhaust
annulus velocity will be the highest.
[ Combined Cycle Output Power Factor ]
(ISO ambient temperature base)
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[Exercise 10.1]
2.5 inHga700 MW, heat rate7826 Btu/kWh.
throttle steam 4 5 inHga7980 throttle steam 4.5 inHga7980
Btu/kWh. .
[Solution 1]
.
HR
KW
A
= A
AHR = {(79807826)/7826}100 = 1.97%
AKW = 1 97/(1+1 97/100)= 1 93%
100
1
HR
KW
A
+
A
AKW = 1.97/(1+1.97/100)= 1.93%
[Solution 2]
HR = Q/W Q = 700,000 kW 7826 Btu/kWh = 5,478.210
6
Btu/hr
W = Q/HR = 686,491 kW
AKW = {(700,000686,491)/700,000}100 = 1.93%
{( 00,000 686, 9 )/ 00,000} 00 93%
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3_Reheat
The steam from boiler flows to the HP turbine
where it expands and is exhausted back to the
boiler for reheating
T
q
RH
3
5
boiler for reheating.
The efficiency of the Rankine cycle can be
improved by reheating on the right hand side of
q
H
4
the T-s diagram.
An improvement in cycle efficiency from a
single reheat is only 2-3% Although this is not
2
w
P
w
T
A
B
single reheat is only 2-3%. Although this is not
dramatic, it is a useful gain which can be
obtained without major modification to the
plant.
q
L
4' 1 6
w
P
s
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3_Reheat
The effect on the cycle efficiency depends on the reheat pressure.
In general, the optimum reheat pressure for maximum cycle efficiency is usually about 1/4 of the main
boiler pressure. boiler pressure.
High reheat pressure gives a high mean temperature of heat reception during reheating, but only a small
extra heat input leading to small increase in cycle efficiency.
L h t i l t t t ith th i l Th f th i Low reheat pressure gives an almost same mean temperature with the main cycle. Therefore, there is no
significant improvement in cycle efficiency.
The pressure drop in the reheater and associated piping is important.
A relatively large pressure drop can significantly offset the benefit due to reheating.
When large diameter piping is used, the pressure drop is reduced, but initial cost may increase
proportionately. As in the main steam pipe, pressure drop in the reheater and its piping must be
appropriately balanced against the initial cost.
The pressure drop in the reheater and associated piping is about 7% to 10%.
This pressure drop results in a poorer power plant heat rate of 0.7% to 1.0%.
As a rule of thumb for the effect of pressure drop on heat rate any place in the steam path is 0.1% poorer
heat arte per 1% pressure drop in a fossil plant.
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3_Reheat
h
D
The trend for higher gas turbine firing and exhaust
temperatures has made reheat combined cycles common.
A
A-B-C: Nonreheat
A-B: HP Turbine
B D: Reheater
A structured, modular approach to the combined cycle
steam turbine product line allows application of non-reheat
steam cycles with advanced gas turbines as well.
B
B-D: Reheater
D-E: IP and LP Turbine
y g
The reheat cycle benefits thermodynamic by adding heat
to the steam cycle at a higher average temperature than to t e stea cyc e at a g e a e age te pe atu e t a
the non-reheat cycle, and by reducing moisture loss in the
low pressure section.
The drier low pressure section expansion reduces the
4%
8%
E
The drier low pressure section expansion reduces the
potential for last stage moisture erosion.
The gain from the reheat cycle is seen as greater steam
turbine output for the same heat to the HRSG 8%
16%
12%
C
turbine output for the same heat to the HRSG.
Reduced heat rejected to the condenser reduces the size
of the cooling system and the amount of cooling flow
required
s
required.
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3_Reheat
Boundary between reheat and non-reheat steam cycle is gas turbine exhaust gas temperature of
approximately 1000F/538C. However, steam turbines for non-reheat cycles are also available when the
EGT exceeds 1000F/538C.
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4_Increasing Steam Pressure
9000
Main Steam conditions strongly influence the
turbine performance.
,

B
t
u
/
k
W
h
9000
At a given pressure the turbine performance
can be improved by increasing the main
steam temperature.
Throttle Pressure
2400 psia
H
e
a
t

R
a
t
e
,
8000
steam temperature.
The higher the steam temperature, the better
the turbine performance.
2400 psia
3500 psia
6 Flows, 30 LSB
Throttle steam 2400 or 3500 psia, 1000 F/ 1000F
T
u
r
b
i
n
e

7000
However, there is a temperature limit beyond
that turbine and boiler will become less
reliable.
Nominal output 700 MW at 1.5 in.Hga.
Turbine Output, MW
200 400 600 800
7000
An increase in steam pressure at turbine inlet
will increase the cycle thermal efficiency.
The casing becomes quite thick as the steam pressure increases, and consequently steam turbines exhibit
large thermal inertia. Therefore, steam turbine must be warmed up and cooled down slowly to minimize the
differential expansion between the rotating blades and the stationary parts. Large steam turbine can take
over ten hours to warm up.
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4_Increasing Steam Pressure
E l i f R ki C l Evolution of Rankine Cycle
T
Ultra Supercritical
Supercritical
1960
1940s
Early 20
th
century
s
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5_Regenerative Feedwater Heating
T
Turbine
4
3
4
Boiler
G
5
1
2
5
1' 5'
condenser
2 3
5
s
1
5
1 5
a b c d
condenser
pump
1
If the liquid heating could be eliminated from the boiler, the average temperature for heat addition would be
increased greatly and equal to the maximum cycle temperature.
I th id l ti R ki l th t i l t d th t bi i d fl i th In the ideal regenerative Rankine cycle, the water circulates around the turbine casing and flows in the
direction opposite to that of the steam flow in the turbine.
Because of the temperature difference, heat is transferred to the water from the steam. However, it can be
id d th t thi i ibl h t t f th t i t h i t th t t f t i
considered that this is a reversible heat transfer process, that is, at each point the temperature of steam is
only infinitesimally higher than the temperature of water.
HIPT
Reversible heat transfer and an infinite number of feedwater heaters would result in a cycle efficiency equal
to the Carnot cycle efficiency.
The greater the number of feedwater heaters used, the higher the cycle efficiency. This is because if a large
number of heaters is used, the process of feedwater heating is more reversible.
However, each additional heaters results in lower incremental heat rate improvement because of the
decreasing benefit of approaching an ideal regenerative cycle.
Th i b fit f dditi l h t i li it d b f th di i i hi i t i l The economic benefit of additional heaters is limited because of the diminishing improvement in cycle
efficiency, increasing capital costs, and turbine physical arrangement limitations.
The amount of steam flow into condenser can be reduced dramatically by the employment of regenerative y y p y g
Rankine cycle.
The LSB problems, such as water droplet erosion and longer active length, could be solved by the
regenerative Rankine cycle which is made by steam extraction in many turbine stages regenerative Rankine cycle, which is made by steam extraction in many turbine stages.
Regenerative Rankine cycle also diminish the influence of the LP turbine, which has worst performance.
HIPT
There are usually no extractions from the steam turbine,
since feedwater heating is generally accomplished
within the HRSG

HIPT
H B l f F il P Pl Heat Balance of a Fossil Power Plant
HIPT
6_LSB
When configuring any steam turbine it is very When configuring any steam turbine, it is very
important to choose the proper annulus area for
the anticipated exhaust flow and condenser
pressure.
W
h
9000
LSB strongly influence the turbine performance.
a
t
e
,

B
t
u
/
k
W
The length of the LSB is determined by the
number of exhaust flows.
In general the longer LSB the lower the full
LSB = 26"
b
i
n
e

H
e
a
t

R
a
8000
30"
33.5"
In general, the longer LSB, the lower the full-
load heat rate.
However under the part-load operation
6 Flows, 2400 psia / 1000 F/ 1000F
Nominal output 700 MW at 1.5 in.Hga.
T
u
r
b
7000
However, under the part load operation,
turbines having longer LSB deteriorate more
rapidly in performance.
Turbine Output, MW
200 400 600 800
HIPT
6_LSB
D 11 S T bi f GE 207FA D-11 Steam Turbine for GE 207FA
195
The best steam turbine choice
for any combined-cycle is
strongly influenced by the site
exhaust pressure which in turn
2 F-40.0"LSB
D-11 steam turbine for GE 207FA,
1800 psia / 1050F / 1050F
W
195
190
It can be seen from this figure
exhaust pressure, which, in turn,
is largely determined by the
temperature of the cooling media.
2 F-33.5"LSB
2 F-30.0"LSB
O
u
t
p
u
t
,

M
W
190
It can be seen from this figure
that the units with largest
annulus area have the best
performance at low back
pressures
a
m

T
u
r
b
i
n
e

185
pressures
However, the units with smaller
exhaust area have better
performance at high back
S
t
e
a
180
performance at high back
pressure because of lower turn-
up loss.
Condenser Pressure, in.Hga
0.5 1.5 1.0 2.5 2.0 3.5 3.0 0.0
175
4.0
HIPT
7_Pressure Drop in Reheater System
The total reheater pressure drop includes
1
2
Turbine Heat
The total reheater pressure drop includes
the pressure drop associated with the
cold reheat piping from HP turbine
exhaust to the reheater section of the
boiler the reheater section of the boiler
a
n
g
e
,

%
0
Turbine Heat
Rate
boiler, the reheater section of the boiler
itself, and the hot reheat piping from the
reheater to the IP turbine intercept valves.
Output
C
h
a
-1
-2
A typical design value for total reheater
system pressure drop is 10% of the HP
turbine exhaust pressure.
R h t P D %
10 15 5
-3
20
For a 1% decrease in reheater pressure
drop, the heat rate and output improve
approximately 0.1% and 0.3%,
respectively
Reheater Pressure Drop, %
respectively.
HIPT
8_EGT vs. ST Output
95
90
When the EGT is lowered, both the
thermodynamic quality of the steam
85
75
80
70
,

M
W
process and the HRSG efficiency
decrease.
Th ff t i d ith th
65
55
60
50
40
b
i
n
e

O
u
t
p
u
t
f
f
i
c
i
e
n
c
y
,

%
The effect is more pronounced with the
single pressure than with a dual or triple-
pressure reheat cycle because the energy
utilization rate falls off faster.
55
45
40
30
20
S
t
e
a
m

T
u
r
b
H
R
S
G

E
f
35
25
400 450 500 550 600 647
10
0
S
Steam turbine output and HRSG efficiency versus gas
400 450 500 550 600 647
GT Exhaust Gas Temperature, C
turbine exhaust temperature for a single-pressure cycle
HIPT
9_Makeup Flow (for Fossil Power)
The makeup is necessary to offset the steam losses in the cycle and losses in the boiler associated with
boiler blowdown and steam soot blowing.
Typical amounts of the steam used for makeup are from 1% to 3% of the throttle flow.
Boiler blowdown is necessary to maintain proper boiler chemistry.
Consideration should also be given to process extractions that involve less than 100% return of condensate.
The makeup water is typically supplied to the condenser hot well increasing the total flow through the The makeup water is typically supplied to the condenser hot well, increasing the total flow through the
heaters and pumps, and therefore must be heated in the feedwater cycle on the way to the boiler.
This additional flow results in higher feedwater heater thermal duties and therefore higher extraction flows,
d hi h i t and higher pump power requirements.
This results in a negative effect on cycle performance.
The effect of makeup on net turbine heat rate is approximately 0.4% higher per percent makeup. The effect
of makeup on output is approximately 0.2% lower per percent makeup.
These values are based on boiler blowdown at saturated conditions at the boiler drum pressure.
HIPT
LP Exhaust Hood 4
HIPT
Typical Exhaust Loss Curve
UEEP = ELEP + Exhaust Loss
The internal efficiency of a
o
w
50
Annulus
Restriction
Loss
steam turbine does not include
the loss at the turbine exhaust
end.
The exhaust loss includes /
l
b
o
f

d
r
y

f
l
o
30
40
Gross Hood
Loss
Total
The exhaust loss includes
(1) actual leaving loss,
(2) gross hood loss,
(3) annulus-restriction loss,
(4) turn-up loss.
s
t

L
o
s
s
,

B
t
u
20
30
Turn-up
Loss
Exhaust
Loss
( ) tu up oss
E
x
h
a
u
s
10
Actual
Leaving
Loss
0
S i
200 400 600 800 1000 1200 1400 1600
0
Loss
Annulus Velocity, fps
Sonic
HIPT
Exhaust Loss [3,600 rpm, GE]
50
46
Bucket Pitch Last stage
Curve length diameter annulus area
no. (inches) (inches) single flow (ft
2
)
1 14 3 52 4 16 3
1
2
3
4
5
2 3 4 5
f
l
o
w
42
38
34
1 14.3 52.4 16.3
1 16.5 57.5 20.7
1 17 52 19.3
1 20 60 26.2
2 23 65.5 32.9
3 26 72 41 1
u
/
l
b

o
f

d
r
y

f
34
30
26
3 26 72 41.1
4 30 85 55.6
5 33.5 90.5 66.1
Van = Annulus velocity (fps)
m = Condenser flow (lb/hr)
u = Saturated dry specific volume (ft
3
/lb)
Aan Annulus area (ft
2
)
u
s
t

L
o
s
s
,

B
t
26
22
18
(1) R d th h t l t th l l it bt i d f
Aan = Annulus area (ft
2
)
Y = Percent moisture at ELEP
ELEP = Expansion line end point at actual
exhaust pressure (Btu/lb)
UEEP = Used energy end point (Btu/lb)
1
E
x
h
a
u
14
10
(1) Read the exhaust loss at the annulus velocity obtained from
the following expression:
Van = {mu(1-0.01Y)} / 3600Aan
(2) The enthalpy of steam entering the condenser is the quantity
obtained from the following expression:
200 400 600 800 1000 1200 1400
6
2
0
UEEP = ELEP + (Exhaust loss)(0.87)(1-0.01Y)(1-0.0065Y)
(3) This exhaust loss includes the loss in internal efficiency
which occurs at light flows as obtained in tests.
Annulus Velocity, ft/s
HIPT
Total Exhaust Loss
W = Work
h
h
T1
h
HL = Hood Loss
LL = Leaving Loss
EL = Exhaust Loss
h
S1
EEL = Effective EL
UEEP = Used Energy End Point (or TEP)
ELEP = Expansion Line End Point
Total Expansion Line
Static
Expansion
Line
W
SEP = Static End Point
AEL = Change in EL
AW = Change in Work
s
B
AEEL = Change in EEL
p
c
= Static Pressure at Turbine
Exhaust Flange
T t l P t L t Bl d E it
EEL
AW=AEEL
LL
EL
h
T2
AEL
p
TB
= Total Pressure at Last Blade Exit
p
SB
= Static Pressure at Last Blade Exit
ELEP
SEP HL
EL
s
HIPT
Steam Turbine Exhaust Size Selection
E h L
Nozzle
Exhaust Loss
[ Velocity triangle in LSB ]
C
2
W
2
U
LSB
U
1
2
3 W
3
C
3
LSB
Minimum LL
4
3
C
3
2
The exhaust area of the steam turbine
5
3
5
should be determined by the balance
between exhaust loss and capital investment
in steam turbine equipment.
4
HIPT
Exhaust Loss
T L Turn-up Loss
Turn-up
Region
Normal Rating Operation Low Load Operation
HIPT
Exhaust Loss
2) T L 2) Turn-up Loss
Water supply line
Water
spray
Water running down
casing walls
p y
LSB
[ Eroded Trailing Edge of LSB near the Hub ] [ Recirculation in the Exhaust Hood ]
casing walls
Recirculating steam
[ Eroded Trailing Edge of LSB near the Hub ] [ Recirculation in the Exhaust Hood ]
HIPT
Trailing Edge Erosion
A crack emanating from a
trailing edge gouge
Trailing edge erosion on the
suction side
Crack in the trailing edge
caused by erosion - PT
y
HIPT
Turn-up Region
HIPT
Turn-up Region
HIPT
Mass Flow at the Exhaust
Price = 00/152 (for LSB installed in one LP cylinder of 500 MW
Korean standard fossil power plants), 2010 .
28 MW ( 17%)
HIPT
LP Exhaust Hood 4
HIPT
Velocity Triangle at Various Loads
Steam turbines designed for
combined cycle employ sliding combined cycle employ sliding
pressure operation.
Ahead of First
Stage Nozzles
Main Steam
Stage Nozzles
After First Stage
Load
[ Sliding Pressure Operation ]
[ Sliding Pressure Operation ]
HIPT
Sliding Pressure Operation
Sliding pressure operation, which is also called variable pressure operation, is a method of controlling
throttle flow and thus power output by varying boiler pressure.
The important factor to be considered when evaluating sliding pressure operation relative to constant throttle
pressure are:
Reduced available energy
Improved HP turbine efficiency
Higher hot reheater temperatures at part loads
Hi h th ttl t t t t l d Higher throttle temperatures at part loads
Reduced power for BFPT and motors driven with variable speed hydraulic couplings
The combined effect of improved HP turbine efficiency and reduced available energy can be evaluated to The combined effect of improved HP turbine efficiency and reduced available energy can be evaluated to
adopt sliding pressure operation.
The live steam pressure can be controlled by adjusting the boiler pressure, i.e. a sliding boiler pressure
control control.
One purpose of this is to reduce the inlet pressure to the first stage with maintained temperature at part
loads.
HIPT
This result in a more stable inlet volumetric flow, which is beneficial for the isentropic turbine efficiency.
Otherwise, the turbine will be operated under the off-design condition.
Both feed pump power and throttling losses in the turbine control valves can be reduced during the part load
operation because of lower pressure.
It requires a fast response of the boiler, therefore, a forced circulation boiler is beneficial.
Reduced pump power at low load operation with variable pressure can be a significant additional heat rate p p p p p g
improvement.
Sliding pressure operation decreases the potential for low cycle thermal fatigue in the turbine during load
changes as compared to constant initial pressure operation changes as compared to constant initial pressure operation.
In sliding operation, first stage exit temperature is almost constant over the load which reduces thermal
stress. (see the Figure shown in next page)
However, with constant initial pressure, and partial arc admission over the load range, the heat rate at light
load is better than the sliding pressure operation heat rate.
HIPT
100
The steam cycle is operated in sliding
pressure mode with fully open steam
turbine valves down to approximately
Fixed Pressure Mode
50
50% live-steam pressure.
The conventional steam plants are
generally operated at a fixed pressure generally operated at a fixed pressure,
that is steam pressure and temperature
remain constant.
Load, %
50
100
Items
+ VWO |
HP Turbine | HP 1 full arc , |
Rankine cycle + available energy +
(
+
(
)
|
HIPT

: ()
: 2014 03 03 (Ver 3)
: 2014. 03. 03 (Ver.3)
: ebyeong @naver.com
Mobile: 010-3122-2262
: /

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It is then heated to the boiling temperature corresponding

The condensate from the condenser or from the steam

Combined Cycle Power Plants 10. Steam Turbines for CCPPs 3 / 78

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