GAS-TURBINE CALCULATIONS

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HRSG Calculations
Turbine Calculations
Condensor Calculations
Pump Calculations
Inputs and Outputs
Cycle Efficiency Calculations
Emission Calculations
State Conditions:Summar

DESIGN RATINGS

Fuel Flow : 23319 kg/hr

Air Flow : 358.4 kg/sec = 1.290E+06 kg/hr
Turbine Exit Gas Temperature : 527.2 C
Power : 107070 kW LHV Heat Rate : 10080 Btu/kW hr
Combustion Reaction :

**Assuming fuel is 100% CH4

Mol. Wt. CH4 : 16.04 g/mol

LHV CH4 : 802.42 kJ/mol

Basis : 1 hr of operation
Mol. Wt. Air : 28.85 g/mol

Mols CH4 =(Mass CH4)/(Molecular Weight CH4) = 1.45E+06 mols

Mols O2 Req'd = 2*(Mols CH4) = 2.91E+06 mols

Mols Air Req'd = (Mols O2 Req'd)/0.21 = 1.38E+07 mols

Mass Air Req'd = (Mols Air Req;d)(Molecular Weight Air) = 3.99E+05 kg/hr

Percent Excess Air

Air Used = Air Flow

Percent Excess Air = 100%*(Supplied Air - Required Air)/(Required Air) = 223.1 %

Combustion Gases : Material Balances

Mols CO2 = Mols CH4 = 1.454E+06

Mols O2 = (Mols Supplied - Mols Required For Combustion) = 6.485E+06
Mols N2 = (Mols O2 Supplied)*79/21 = 3.533E+07
Mols H2O = 2*Mols CH4 = 2.907E+06

LHV Heat Rate and Efficiency

Heat Rate = 10080 Btu/kWhr

= 0.3385
= 33.85 %

Energy Balance on Gas Turbine

Datum : 25 C All Gases

Energy Balance:

Assume air and fuel enter at 25 C, therefore HIN = 0

- HRXN = Apparent LHV

Enthalpies of Exit Gases

TDATUM hOUT
Component a b c d T (K) moles HOUT (kJ)
(K) (J/mole)
1.92E- 1.06E- -3.60E-
H2O 32.24 800.4 298.0 18075.3 2.907E+06 5.25E+07
03 05 09
-1.57E- 8.08E- -2.87E-
N2 28.9 800.4 298.0 15105.8 3.533E+07 5.34E+08
03 06 09
1.52E- -7.16E- 1.31E-
O2 25.48 800.4 298.0 15966.4 6.485E+06 1.04E+08
02 06 09
5.98E- -3.50E- 7.47E-
CO2 22.26 800.4 298.0 22761.1 1.454E+06 3.31E+07
02 05 09
Total 7.23E+08

Work Produced

Work (W) =Power*Time = 3.855E+08 kJ

delta HRXN

HRXN =(LHV CH4)(Mols CH4) = -1.139E+09 kJ

Q=HOUT + W + HRXN = -3.033E+07 kJ

HRSG CALCULATIONS

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Gas-Turbine Calculations
Turbine Calculations
Condensor Calculations
Pump Calculations
Inputs and Outputs
Cycle Efficiency Calculations
Emission Calculations
State Conditions:Summar

Energy Balance

Assuming an Exhaust Temperature : 150.0 C

TDATUM hOUT HOUT

Component a b c d T (K) moles
(K) (J/mole) (kJ)
 1.92E- 1.06E- -3.60E-
H2O 32.24 423.2 298.0 4273.3 2.907E+06 1.24E+07
03 05 09
-1.57E- 8.08E- -2.87E-
N2 28.9 423.2 298.0 3661.4 3.533E+07 1.29E+08
03 06 09
1.52E- -7.16E- 1.31E-
O2 25.48 423.2 298.0 3765.1 6.485E+06 2.44E+07
02 06 09
5.98E- -3.50E- 7.47E-
CO2 22.26 423.2 298.0 4954.6 1.454E+06 7.20E+06
02 05 09
Total 1.73E+08

PIN=POUT and TOUT are design parameters. TIN is obtaind from calculations from the pump.

H2O IN (State 2) OUT (State 3)

T (C) 45.81 500
P (kPa) 7000 7000
State Compressed Liquid Superheated Vapour
h (kJ/kg) 200.14 3410.3
s (kJ/kg K) 0.6751 6.7975

Enthalpies (NOTE : Basis of 1 hour of operation)

1) Steam Cycle Condensate 200.14 kJ/kg

2) Steam Cycle Steam 3410.3 kJ/kg
3) Gas Cycle Exhaust from Turbine 7.23E+08 kJ
4) Gas Cycle Exhaust to Air 1.73E+08 kJ

Thermal Efficiency = (EnthalpyTURBINE -EnthalpyEXHAUST TO AIR)/EnthalpyTURBINE = 76.0 %

Steam Produced in Steam Cycle

Mass Flow of Working Fluid in Steam Cycle

= ( Enthalpy Across Gas Turbine Side of HRSG)3-4/( Enthalpy Across Steam Turbine Cycle
Side of HRSG)1-2
= 1.71E+05 kg/hr
= 47.55 kg/sec

TURBINE CALCULATIONS
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Gas-Turbine Calculations
HRSG Calculations
Condensor Calculations
Pump Calculations
Inputs and Outputs
Cycle Efficiency Calculations
Emission Calculations
State Conditions:Summary

TURBINE : Energy Balance

Isentropic Expansion to 10 kPa

IN (State 3) OUT (State 4 Isentropic)

 T (C) 500 45.81

P
7000 10
(kPa)

Superheated
State liquid vapour mixture
Vapour

h
3410.3 191.83 2584.7 2153.2
(kJ/kg)

s
6.7975 0.6493 8.1502 6.7975
(kJ/kg K)

x
(vapour 0 1 0.820
fraction)

x is first determined from : 6.7975 = x(8.1502) + (1-x)(0.6493)

h is then determined from : h = x(2392.8) + (1-x)(191.83)

45.81 C is the saturation temperature at 10 kPa

wISENTROPIC = hIN - hOUT

wISENTROPIC = 1257.1 kJ/kg Work done if expansion is isentropic.

The actual expansion is not isentropic. The isentropic efficiency of the turbine is defined :

For modern turbines an efficiency of 85% is acheivable. Therefore

wACTUAL = (0.85)(1257.5 kJ/kg)

wACTUAL = 1068.6 kJ/kg

hOUT can be determined from :

hOUT = 2341.7 kJ/kg

Conditions for actual expansion to 10 kPa

 IN (State 3) OUT (State 4 Isentropic)

T (C) 500 45.81

P
7000 10
(kPa)

Superheated
State liquid vapour mixture
Vapour

h
3410.3 191.83 2584.7 2341.7
(kJ/kg)

s
6.7975 0.6493 8.1502 7.3885
(kJ/kg K)

x
(vapour 0 1 0.90
fraction)

x v (m3/kg)
0 0.00101
1 14.67

By interpolation : v = 13.18 m3/kg

Power = wACTUAL*(Mass Flow Rate of Steam) = (1068.6 kJ/kg)(66.9 kg/sec) = 50.8 MW

CONDENSOR CALCULATIONS
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Gas-Turbine Calculations
HRSG Calculations
Turbine Calculations
Condensor Calculations
Pump Calculations
Inputs and Outputs
Cycle Efficiency Calculations
Emission Calculations
State Conditions:Summary

Condensor Energy Balance

IN OUT
H2O
(State 4) (State 1)

T
(°C)
45.81 45.81

P
(kPa)
10 10
 Saturated
State Liquid Vapour Mixture
Liquid

h
(kJ/kg)
191.83 2584.7 2341.7 191.83

s
(kJ/kg K)
0.6493 8.1502 7.40011 0.65

x 0 1 0.9 0.00

Q = (66.9 kg/sec)(191.83 - 2341.7) = -102.2 MW

That is, 102.2 MW of heat is rejected to the environment at low temperature.

PUMP CALCULATIONS
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Gas-Turbine Calculations
HRSG Calculations
Turbine Calculations
Condensor Calculations
Inputs and Outputs
Cycle Efficiency Calculations
Emission Calculations
State Conditions:Summary
PUMP Energy Balance

The isentropic work for an incompressible fluid is given by

Isentropic compression to 7 Mpa

IN OUT
(State 1) (State 2, Isentropic)

T (C) 45.81 47.5

P
10 7000
(kPa)

State Sat'd Liquid Compressed Liquid

h
(kJ/kg) 191.83 198.89
 s
0.6493 0.6493
(kJ/kg K)

x 0 0

v
0.00101 0.00101
(m3/kg)

T2 is found using the following table at 7000 kPa

T (°C) h (kJ/kg)

45 188.45

50 209.33

By interpolation T2 = 47.5 C

wISENTROPIC is calculated by

wISENTROPIC = (0.00101 m3/kg)(10-7000)kPa = -7.06 kW *The negative sign indicates that work is being
done ON the system.

hOUT is calculated by

hOUT = 191.83 + 7.06 = 198.89 kJ/kg

The actual compression is not isentropic. The isentropic efficiency of the pump is defined as

For a well designed pump an efficiency of 85% is acheivable.

Therefore
wACTUAL = (-7.05kJ/kg)/0.85 = - 8.31 kJ/kg

Actual compression to 7 MPa

IN (State 1) OUT (State 2, Actual)

T
45.81 47.8
(°C)

P
10 7000
(kPa)

State Sat'd Liquid Compressed Liquid

h
191.83 200.14
(kJ/kg)

s
0.6493 0.6751
(kJ/kg K)

x 0 0

v
0.00101 0.00101
(m3/kg)

hOUT = 191.83+8.31 = 200.14 kJ/kg

T2 and s2 are found using the following table at 7000 kPa

h s
T (°C)
(kJ/kg) (kJ/kg K)

45 188.45 0.6387

50 209.33 0.7038

By interpolation
 T2 = 47.8 °C

s2 = 0.6751 kJ/kg K

The power delivered to the pump is then calculated as

P=w*(Mass Flow Rate of Steam) = (9.31 kJ/kg)(93.6 kg/sec) = 777.3 kW

CYCLE INPUTS AND OUTPUTS

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Gas-Turbine Calculations
HRSG Calculations
Turbine Calculations
Condensor Calculations
Pump Calculations
Emission Calculations
State Conditions:Summary

Power Generated By Gas Turbine Heat Rejected By Condensor

= 107.07 MW = 102.2 MW

Power Generated By Steam Turbine Heat Input To Cycle (LHV)

= (Apparent LHV)(Fuel Flow Rate)
= 50.8 MW = 316.3 MW

Power Required By Pump Approximate Heat Input To Cycle (HHV)

= (Apparent LHV + Heat of Vapourization of Water)(Fuel Flow Rate)
= 394.9 kW = 351.9 MW

CYCLE EFFICIENCY
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Gas-Turbine Calculations
HRSG Calculations
Turbine Calculations
Condensor Calculations
Inputs and Outputs
Emission Calculations
State Conditions:Summary

Thermal Efficiency (LHV) = (Net Work)/(Heat Input LHV) = 0.498 = 49.8 %

Approximate Thermal Efficiency (HHV) = (Net Work)/(Heat Input HHV) = 0.448 = 44.8 %

Equivalent Carnot Efficiency = 1-TLOW/THIGH = 60.1 %

EMISSION CALCULATIONS
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Gas-Turbine Calculations
HRSG Calculations
Turbine Calculations
Condensor Calculations
Inputs and Outputs
Pump Calculations
State Conditions:Summary

NOx Calculations
Using the US EPA Compilation of Emission Factors Document AP-42
Heat Input (LHV) = (Mols Fuel)(LHV Fuel)
= 1.139E+09 kJ/hr

Total Power Delivered

= (Power from Gas and Steam Turbines - Power Required By Pump)
= 157483 kW

(Natural Gas Flow Rate m3/hr)(0.189 g NOx/MJ Fuel Input)

= 215.4 kg/hr
= 1888.2 tonne/yr
NOx / kW hr = (Mass Flow Rate NOx)/Net Power = 1.37 g NOx / kW hr

CO2 Calculations
= 6.397E+04 kg/hr = 560757 tonne/yr
CO2 /kW hr = (Mass Flow Rate CO2)/(Net Power) = 406 g CO2 / kW hr
SO2 Calculations
Using the US EPA Compilation of Emission Factors Document AP-42

Emission Factor :9.6 kg SO2/1E6 m3 fuel

burned
Using the ideal gas law: R = 8.20575E-05 atm m3/mol K

Volume CH4 = nRT/P = 35562 m3/hr

= (Natural Gas Flow Rate m3/hr)(9.6 kg SO2 /1E6 m3 fuel burned)
= 0.341 kg/hr
= 2.99 tonne/yr

SO2 / kW hr = (Mass Flow Rate SO2)/Net Power = 0.00217 g SO2 / kW hr

CO Calculations
Using the US EPA Compilation of Emission Factors Document AP-42
Heat Input (LHV) = (Mols Fuel)(LHV Fuel) 1.139E+09 kJ/hr

Emission Factor : 0.047 g/MJ fuel input

= (Natural Gas Flow Rate m3/hr)(640 kg CO /1E6 m3 fuel burned)
= 53.9 kg/hr
= 472.0 tonne/yr
CO/kW hr = (Mass Flow Rate CO)/Net Power = 0.342 g CO/kw hr

STATE CONDITIONS : SUMMARY

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Gas-Turbine Calculations
HRSG Calculations
Turbine Calculations
Condensor Calculations
Inputs and Outputs
Pump Calculations
Emission Calculations

Working Fluid : Water

Conditions at Different States Within The Cycle

Mass Flow Rate Air 1290274 kg/hr

Mass Flow Rate Fuel 23319 kg/hr
Mass Flow Rate Steam 171173 kg/hr

Property State 1 State 2 State 3 State 4

45.81 47.8 500.0 45.81

T (C)

P
(kPa)
10 7000 7000.0 10

State Sat'd Liquid Compressed Liquid Superheated Vapour Liquid Vapour Mixture

h
(kJ/kg)
191.83 200.14 3410.3 191.83 2584.7 2341.7

s
(kJ/kg K)
0.6493 0.6857 6.7975 0.6493 8.1502 7.40011

x
(Vapour Fraction)
0 0 1.0 0 1 0.90

v
(m3/kg)
0.00101 0.00101 0.04814 0.00101 14.67 13.20

Efficiency of the gas turbine

The total energy balance in a gas turbine can be summarized as

Total energy input = Compressor load + Generator power output + Flue gas energy loss +
rotational losses
with the exception of the rotational losses all others can be calculated in a easy manner , what
you need is the following information.

1. Calorific value of the fuel (kcal/kg)

2. Mass flow rate of the fuel (kg/s or t/hr) (if only the volume flow is available then you need to
know the density of the fuel)

3. air flow into the turbine ( this is tricky most of the sites do not have a air flow meter , you have
to get it from the characteristic graphs which GE provides , you can also get the value form the
site acceptance test or the performance guarantee test done at commissioning)

if you have a HRSG , which you probably will have then you can calculate the efficiency of the
HRSG and also the combined efficient of the total co generation power plant, for this you need
the additional data

Note - i do not know the layout of your plant or its operating nature , i am assuming that the
steam used for deaeration is got from the plant itself and CPH if present is inside the HRSG
itself. you need to work out the details yourself , i am giving the calculations for a self sustaining
plant. ie it takes only water at room temp and fuel and gives out power and steam. The plant
axillary consumption which will be around 2-4% of the plant full load is neglected in the
calculation. mainly because i do not have sufficient data.

The basic equations for the calculation are

For GT
Efficiency = 860*MW output (MwHr) / (fuel flow(kg) * calorific
value of fuel(in kcal/kg))
this is the base formula where fuel flow is normally available in M3 which
you have to convert to mass with the known density.

for HRSG
efficiency (overall) = steam flow rate * enthalpy of steam /
(HRSG inlet temp * 0.25 * air flow rate)

efficiency (heat exchanger) = steam flow rate * enthalpy of

steam / ( (HRSG inlet temp - HRSG outlet temp) * 0.25 * air flow rate)

the combined efficiency of the co generation is given by

efficiency = ( (860*MW output (MwHr)) + steam flow rate *

enthalpy of steam) / (fuel flow(kg) * calorific value of fuel(in kcal/kg))

sample calculation

I am now in a frame 5 site , so i am taking the daily production readings from

here. the values at your site will be different
Naptha consumption = 192m3
Power generation = 379 Mwhr
Average power generation / hr = 15.8 MW
Calorific value of naptha = 11250 kcal/kg
Naptha density = 0.7

Energy balance in Gasturbine

inlet ambient air = 25 deg

cdp = 6.8kg/cm2
ctd = 302 deg
exhaust = 507 deg
fuel input = 1.7 kg/s
calorific value of naptha = 11250 kcal/kg
density of naptha = 0.71
power = 16 MW
air flow into the turbine = 360 t/hr
specific heat capacity of air = 0.25 kcal/kg deg

input energy into the turbine = fuel input + air input

fuel input = 1.7 * 3.6 * 11250 *(1000) kcal
= 68850 Mcal
air input = 360 * 0.25 * 302
= 27180 Mcal

total energy input to the turbine = 96030 Mcal

power output from the generator = 16*860

= 13760 Mcal

flue gas losses = (360+1.6*3.6)*0.25*507

= 46390 Mcal

compressor load and rotational losses = 96030 - (46390 + 13760)

= 96030 - 60150
= 35880 Mcal

this equated in terms of power = 35880/860

= 41 MW

the compressor load does not change much with the loading of the machine , you will see that for
a 20 MW gasturbine , the compressor load is about 40MW.

And CSA , are you sure about 30-35% efficiencies ?? to the best of my knowledge GT simple
cycle efficiencies does not exceed 25 +/- 2 %.

the HRSG is a twin drum and produces two different steam varities one a VHP
steam at 48Kg/cm2 and 435 deg and other MP steam at 18kg/cm2 at 245 deg
Enthalpy of VHP steam = 785 kcal/kg
Enthalpy of IP steam = 692 kcal/kg
VHP steam production = 805 tonnes
average steam production / hr = 33.5 t/hr
MP steam production = 99 tonnes
average MP steam production /hr = 4.12 t/hr

HRSG inlet temperature = average GT exhaust temp

= 490 deg
HRSG outlet temperature = average stack temperature
= 140 deg
ambient temperature = 32 deg

air flow rate - the air flow for a frame 5 machine at site condition (32 deg
ambient) is 408 tonnes at 85 deg IGV opening , as the machine was put in cogen
cycle and the average IGV opening is 56 deg , from the chara graph the air
flow is estimated as 364 tonnes.

so

GT efficiency = (860 * 379 *100) / ( 192 * 0.7 * 11250)

= 21.57 %

HRSG efficiency (overall) = ( ( 33.5 * (785-30) ) + (4.12 * (692-30) ) ) /

( 490 * 0.25 * 364) ( here stack losses are taken into account)
= 62.83 %
HRSG efficiency (heat exchanger) = ( ( 33.5 * (785-30) ) + (4.12 * (692-30) )
) / ( (490-140) * 0.25 * 364) ( here stack lossses not taken into account)
= 88 %

overall co-generation efficiency

= (860 * 379) + ( ( 805 * (785-30) ) + (99 * (692-30)
) ) / ( 192 * 0.7 * 11250)
= 67 %

uiries and answers :)

Quiery 1

" And then this just falls apart. In the calculations, nowhere does it mention the compressor load
or provide any indication of a sample value for rotational losses. There's no mention of air flow
or how the value 860 came into the formula nor what it represents."

ok , i kinda assumed that people will be familiar with the joules constant , power energy
equivalency now i have to derive the formulas as well i guess. well here goes

Power energy equivalents

1 kilowatt (KW) = 1 kilo joule/ sec

1 kilowatt sec ( Kw s) = 1 kilo joule

converting sec to hours , as Kw Hr is the standard for electrical energy
measurement
1 kilowatt hour (Kw Hr) = 3600 Kilo joule

now we know

1 calorie = 4.187 joules , this is the joules constant so

1 Kilo calorie = 4.187 Kilo joules

1 kilo joules = 0.23883 Kilo calories

so

1 Kilowatt hour (Kw Hr) = 3600 * 0.23883 Kilo calories

= 859.80416 Kilo calories
= 860 kilo calories ( this is a reasonable
approximation)

this is the electrical energy and heat energy equivalence . This is how the
860 in the formula came from.

Efficiency of the gas turbine

efficiency of the turbine = energy equivalent of generator Generator power

output / energy input into the turbine

energy equivalent of generator Generator power output = 860 * Kw-Hr

energy input into the turbine = Calorific value of the fuel (Kcal /kg) * fuel
flow ( Kg/hr)

= 860 * Kw-hr / Calorific value of the fuel

(Kcal /kg) * fuel flow ( Kg/hr)

now multiplying both the numerator and denominator by thousand

= 860 * Kw-hr * 1000 / Calorific value of the
fuel (Kcal /kg) * fuel flow ( Kg/hr) * 1000

this converts the Kw-Hr to Mw-Hr and kg/hr to t/hr

= 860 * Mw-hr / calorific value of the fuel
(Kcal/kg) * fuel flow ( t/hr)

so this is how the energy efficiency of the gas turbine is derived.

i am also deriving a formula for heat rate of the turbine to the efficiency

heat rate of the turbine is defined as the The ratio of fuel energy input as
heat per unit of net work output. It is expressed mostly in Btu/Kwhr or in kj

/Kwhr . I am not a fan of Btu , but i am a ardent fan of SI units :) so i will

derive the equation here in Si units.
Heat rate = Kj/ Kwhr

Efficiency = KwHr * 3600 / Kj

Efficiency = 3600 / (kj/kwhr)

efficiency = 3600 / Heat rate

as far as the rotational and compressor loads are concerned i have given the
calculation in the next post. Please go through it.

Quiery 2

" Just doing a quick search of wikipedia.org, more than one article suggests the thermal
efficiency of simple-cycle gas turbines is approximately 30-40%, and that combined cycle gas
turbine efficiencies are as high as 60%. GE used to market one of their aero-derivative packages
as a "40-40" machine because it had 40% thermal efficiency for 40 MW, and that's darned high
for a simple cycle machine (that had to have inlet cooling to achieve the 40-40 moniker).

But, ProcessValue needs to patent the plant at his site, and quick. Because a thermal efficiency of
67% is exceptional.

And unrealistic. Particularly if the Frame 5 is only putting out an average of 15.8 MW per hour,
which is very low if the unit is operating at Base Load, which is when the efficiency would be
highest and when most performance guarantee tests are run. And even more unrealistic if the GT
efficiency is only 21.57%."

I did a quick search through my GE manuals and i came up with this. I am uploading a small
document , a GE document which has the heat rate for its line of gas turbines.

http://www.2shared.com/document/VUjnzbcw/GEgasTurbine.html

heat rate for a distillate fired frame 5 machine is given as 12847 kj/kw-hr . from the efficiency to
heat rate equation derived above it calculates to an efficiency of 28% max. this is the full load
efficiency of the machine at iso conditions , at 26 MW , air flow of 450 t/hr pressure ratio of 10.6
etc .... please refer the doc. this is seldom achieved in real life. Base load of the machine at site
conditions is 21.5 MW , and the supplier BHEL doc gives a assured heat rate of 3390 kcal/kwhr
as the heat rate , ie the base load efficiency of the machine is 25 %. thus for a machine running at
a part load of 15 MW an efficiency of 22% is not unrealistic. its just the way the machine is.

wikipedia provides good answers , most of the time it is quite right, but 40% efficiency is way
higher and i will bet on the GE manual than wiki.

now that we mention it , frame 9 machine seems to have the lowest heat rate on a gas fired
machine , 9930. this equates to a efficiency of 34%. i have contacted my friend in NTPC , he will
give the data on the fame 9 machine they are running , but he assured me that they get close to
30% efficiency at base load operation. it seems that the smaller machines have a higher heat rate
and thus a lower efficiency. machines in refineries are mostly frame 6. they also do not fare well.
not above 25-26%.

and about the cycle efficiencies. I calculated the efficiency of a co-generation power plant , not a
combined cycle power plant. in a co-generation power plant the plant output is both power and
steam. in a combined cycle power plant the plant output is power only. the steam from the HRSG
is routed to a steam turbine to produce power. combined cycle power plants have a lower
efficiency than co generation power plants. in co generation power plants the heat equivalent of
the steam generated is taken as the output. this gives them a higher efficiency than a combined
cycle power plant.

in a combined cycle power plant , the steam is used to run a steam turbine at the downstream
which has a 30% efficiency due to the condenser losses.

in a cogeneration cycle power plant as the steam equivalent is directly taken , this 70% reduction
in efficiency does not come into play. only the stack losses are accounted for.

this is the reason why the efficiencies of a co generation plant is higher than a combined cycle
power plant.

combined cycle gives efficiencies in the range of 50 - 60% while co- generation system give
efficiency of 70-80 %. the plant efficiency shown in the calculation is quite low as it was
operating in part load conditions.

So i do not think i need to go and patent my site , unfortunately it is running at kinda low
efficiencies. all refineries and process plants which operate the gas turbine at part loads have the
same situation.

So my concluding remarks are , my calculations and math are quite right. there are no deviations
in the equations or in the values provided.

and one last thing , i just saw CSA's post now

" Let's see, if the total power produced by the gas turbine in your example is 60 MW (20 MW
generator output + 40 MW compressor load), then isn't 20 MW (the output rating of the gas
turbine) 1/3 (33%) of 60 MW? So, roughly two of every three horsepower produced by the gas
turbine are used to drive the compressor, and only one of every three horsepower is available to
drive the generator? "

well CSA you are talking about only the useful power output from the turbine. ( ok the
compressor load is not got as useful power , but i am taking it as the work done by the turbine) .
but every heat engine needs to reject out certain heat , in gas turbines it is in the form of flue
gases , that should also be accounted as a loss is it not ??
Speed is a substtitute for accurancy. LOL , as long as you cover up / rectify your mistakes as
soon as you make them , no one is going to notice right ;) . just trying to lighten up the serious
discussion :)

Steam turbine
Efficiency of the steam turbine

Kurush , steam turbine power plants have only 30% efficiency , i do not know from where you
got 75% efficiency and all . i am giving a sample calculation again.

if you look at the above equations you will see that 1 MWhr is equivalent to 860*1000 kcal of
energy.

let us suppose that i am having a fully condensing turbine , with input 90Kg and 500 deg steam
and condenser operating at vacuum of -0.9 kg/cm2 and a dynuss fraction of 0.85

the enthalpy of the input steam is given by = 812 kcal/kg

enthalpy of steam going into the condenser is given by = 533 kcal/kg

the heat energy available for the turbine to convert to work is = 812 - 533
= 280 kcal/kg

the heat energy which goes to the condenser is lost , this is what i was referring to the condenser
losses.

assuming that turbine has no rotational and radiation losses , they will be small , so they can be
neglected you can see that for producing 1 MW output you will need 860/280 = 3.1 tonnes of
steam at 90 kg pressure and 500 deg. thus the efficiency can be calculated as

efficiency of the steam turbine = 860/(3.1*812)

= 34.12 %

well , now you see that neglecting all the losses i get a ideal steam turbine efficiency as 34%
only. i have not taken into account that the boiler will be only 88% efficient , there will be
extraction steam for deaeration etc . if you have all the data , and if you calculate you will see
that the efficiency of a conventional steam power plant is only 30% +- 2% .

I calculated the efficiency of the steam turbine only. which part of it did you not understand. you
have said the you have a steam turbine running right, with the equations above calculate the
efficiency yourself you will get to know.

efficiency of a fully condensing turbine is given by

= 860 * power output of the turbine / ( inlet steam flow (t/hr) * enthalpy of steam kcal/kg)
once again i say steam turbines have 30-35% efficiency only.

if you need any second reference , i suggest you look into power plant engineering by black &
veatch, or PK Nag or steam plant operation by lammers and woodruff. it will give you good idea
about how to calculate steam turbine efficiencies and also a overall idea about design and
operation of steam turbines and power plants in general.

in a combined cycle power plant, the

>steam is used to run a steam turbine at
>the downstream which has a 30%
>efficiency due to the condenser losses.
>
>Sir, please explain where you got this
>number for steam turbine efficiency.
>Steam turbines are pretty good at
>extracting the energy from the steam--I
>have no reference off hand, but I think
>75%+ is not an unheard of number

Probably you are referring to isentropic or cylinder efficiency. In this case 75% is the least you
can expect. It can be as high as 90%. Isentropic efficiency is the ratio between the actual
expansion power to the theoretical expansion power assuming the expansion takes place at
constant entropy.

As far as thermal efficiency is concern you can find somewhere around 45% for a big ST
(1000MW), 3-pressure type. Thermal efficiency for the steam cycle (exclude boiler) is the ratio
between the total expansion power to the total energy received by the steam cycle.

In practice probably we use net change in enthalpy between two terminals of your compressor,
namely enthalpy of air at compressor discharge and enthalpy of ambient air. In this case you are
assuming intake filter is a part of your compressor. You can do correction to normalize work
done to overcome filter differential separately.

In order for you to know enthalpies at both terminals you have to measure mainly:

Ambient air: Temp & pressure

Compressor discharge : Temp & pressure

These 2 sets of data in fact defined enthalpies of ambient air and at comp discharge. You can use
standard table for properties of air to get the desired enthalpies.

Enthalpy diff between these two terminals in defined work done to compress each kg or air.
Obviously this is done by the compressor. The engineering unit shall be in Joule/kg.
Finally you have to know air mass flow rate (kg/s). Here is tricky part since it is rare you have
measurement for that. The best & also one of the standard methods used is via index pressure.
Basically this method utilizes index pressure changes to predict deviation of air mass flow when
compared to the known reference (e.g. commissioning data).

In brief your calculation should look like this one.

Enthalpy change across comp = h2(P2,T2)- h1(P1,T1)

= Delta h (J/kg)

Compressor input power = (Delta h)*dm_air/dt (J/s)

The most critical parameter to get good result is to get accurate value for dm_air/dt.

What I mentioned above is very simplified task. Depends on your applications more often you
have to do a lot more fine tuning/correction/normalization to ensure what you are measuring
serves the intended purpose.

The temperature is 1050 deg C and the

> mass flow rate is 33 kg/sec.120.54 t/hr.

Ok. Let us calculate how much you can get within 3% accuracy.

High temperature reservoir of flu gas = 1050 Cel

Lower temperature reservoir of flu gas = 100 Cel (The current practice based on 30 Cel ambient
air-My country)

Flu gas temp gradient = 1050-100= 950 Cel

Average temperature gradient = [(1050+273)+(100+273])*0.5= 846 Kelvin

Cp_air @ 848 K= 1.11kJ/kgK http://www.engineeringtoolbox.com/dry-air-properties-d_973.html

Heat available from flu gas

Q_flugas =Cp_air (T_inlet-T outle)* dM/dt

= 1.11 X 10^3 X( 1323-373)X 33 Joule/s

= 3.48 X 10^7J/s

= 34.8MW
Boiler efficiency can be approximated to be around 0.88 (66%)

Therefore, heat energy that can be absorbed by steam cycle = 0.88 X 34.8 = 30.62MW

I think at most ST will be two pressure type. Its thermal efficiency is estimated to be around 0.33
(33%)- I might be wrong by the order of +/-2% here.

Thus, the gross output you can get will be

P_gross =0.33* 30.62 = 10.1MW

Not to judge, but I am trying to understand your way of calculating exhaust energy.

Q=m/dt*Cp*(T_inlet-T_outlet)

As Cp, why you take air? Isn't that must be flue gas specific heat?

An example:
Based on gas turbines technical data:
Output Power: 15.290 kW
Heat Rate: 9940 kJ/kWh
Exhaust Flow: 180.050 kg/h
Exhaust Temp: 505 C
Engine Efficiency: 36,2 %
LHV Natural gas: 9,722 kWh/m

Input Energy: 15.290/0,362=42.237,5 kW

Energy Loss: 1-0,362=0,628 (62,8%)

According to your assumption, Energy Loss should be bigger than the exhaust energy. Lets use
your way of calculating exhaust energy:

Exhaust flue gas temp:505C

High temperature reservoir of flu gas = 505C
Lower temperature reservoir of flu gas =100C

Average temperature gradient=(505+100)/2=302,5C = 575,6 K

Cp_air=1,04 kJ/kg-K

The usable energy can be calculated as:

Q_usable=50*1,04*(505-100)
Q_usable=21.060 kW
If considered the total extent of exhaust energy, then the output reference temperature must be
equal to ambient temperature, lets take 30C.

Q_exhaust=50*1,04*(505-30)
Q_exhaust=24.700 kW

But;

Input energy was 42237 kW (100%)

Output power is 15290 kW (36,2%)
Exhaust energy is 24700 kW (58,5%)

From this calculation, the total energy losses should be 62,8%. If exhaust energy is 58,5%, this
means the rest is only 4,3% which must be the combination of energy losses through the turbine
cooling, friction, heat losses etc. 4,3% doesn't seem realistic to me.

Droop and Isochronous Modes ,Speed logic

There was a time when GE-design heavy duty gas turbine control used Isochronous speed
control mode during synchronization (FSNL operation), and then was switched to Droop speed
control mode when the generator breaker was closed (this was also common for many older GE
steam turbine control systems). Exactly when it became common for GE-design heavy duty gas
turbines to operate in Droop speed control mode during synchronization (FSNL operation) I'm
not sure. I know that in Mark IV digital Speedtronic turbine control systems the gas turbine was
operating in Droop speed control mode during synchronization (FSNL), and had to be switched
to Isochronous when appropriate (either manually or automatically, again--if Isochronous speed
control mode was possible in the control system; Isochronous speed control mode was
considered an option on Mark IV Speedtronic turbine control systems).

Without being able to see the Mark I Speedtronic elementary for the site, it's very difficult to say
for certain how the control system for the turbine in question knows if it is to be in Droop or
Isochronous Speed Control. Typically, there is an input (discrete; contact input) from the utility
tie breaker that is used to tell the Speedtronic whether or not it will be, or is, connected to a grid.
If the tie breaker is open, the contact input would tell the control system to be in Isochronous; if
the tie breaker was closed, it would tell the control system to be in Droop.

HOWEVER, a contact input wasn't always used to automatically switch between Droop and
Isochronous. And, some control systems didn't have even a manual switch for the operators to
switch between Droop and Isochronous speed control. Many units were only designed to be
operated in Droop speed control mode--even black start machines, though most black start
machines could be operated in Isochronous mode. But, the selection wasn't always automatic as
has been said.

Most GE-design heavy duty gas turbines operating in Droop speed control mode will handle
small loads when isolated from a grid (in "island" mode, when Isochronous mode should be
selected) pretty well without too much drop in frequency. But, if Isochronous speed control mode
is enabled the control system should be able to control frequency all the way from zero load up
to the machine's power output rating very well.

But, it would really be necessary to look at the Speedtronic elementary for the machine in
question to be able to say whether or not is has the ability to automatically switch between Droop
and Isochronous speed control modes, or whether it's incumbent on the operator to know if
Droop or Isochronous speed control mode should be selected and to select it when appropriate.
Or, whether the unit has the ability for the operator to select between Droop and Isochronous
speed control modes. Some units were programmed to use the utility tie breaker status contact
input to prevent an operator from selecting Isochronous speed control mode unless the utility tie
breaker was open, but wouldn't automatically select Isochronous speed control mode if the utility
tie breaker was open or opened.

So, it's really necessary to look at the site-specific Speedtronic elementary, and possibly the
Generator Control Panel Elementary as well, to see how the selection of Droop and Isochronous
is made--indeed, if it's even possible. (Most GE-design heavy duty gas turbine control systems
had the capability for both Droop and Isochronous speed control modes, but Isochronous speed
control mode wasn't always enabled as it was sometimes considered a purchased option.)

Older machine GE frame 5 with speedtronic Mark 1. This machine is to operate on

the grid but also as a black start (isochronous). On the grid is clear cut - 4% droop,
load limited by exhaust temperature.

Isochronous however, I am unclear. We have performed black start testing which

goes well, but only have placed minimum load on the machine. Will the unit behave
like "normal" when carrying high loads? The manual states " normally operate in
parallel with 4% droop. However, when operated alone zero droop may be
selected." To my knowledge the operators do not physically select droop or
isochronous mode. I think we are always in droop mode. The question is; does
speedtronic somehow know when it should be isochronous or parallel? and does it
automatically transfer between modes? Or does it just stay in droop mode which
inherently works when isochronous?

GE gas turbines water wash. in DLN gas turbines water wash should
be done at base load
In GE 7Fa we are doing online water wash at a reduced load approximately by 3%.
Machine should be out of temperature control, transitioning to speed control. This is
done to avoid peaking of the machine during the water washing.

To my knowledge for F class machines no need to reduce the load while doing on line water
wash.

venu
Dear GE Gas Turbines,
We perform an online rinse/wash to our GE7EA DLN 1.0 turbines daily. GE specifies that the
online wash should be done at base load only with IGV's at maximum angle and IBH the inlet
bleed heat valve closed. Keeping the IGV's at or near maximum angle reduces chances of water
droplets hiding out in low pressure zones of the IGV blades and contributes to a better wash.

If you do not keep the unit on temp control you should watch your IGV angle, since you can
expect a 3-5% rise in power output during a wash, which could cause the IGV's to close down in
an attempt to maintain exhaust temperature. You do not specify the model of turbine you are
using, but I can tell you that on the 7EA inlet bleed heat is closed with IGV angle greater than 61
deg, so IBH should never be a problem if the unit is at or near base load.

As a sidenote we have modified logic to monitor the secondary flame detector intensity and stop
the wash if 2 flame detectors fall below a set threshold. We have noted in colder ambients that
the increased moisture from the wash seems to fog over the flame scanners at times.

I would like to add one more point that online washing should not be conducted when the Inlet
bleed heat is open. This valve should not be forced to close to carry out the water wash.

Turbine should be in running condition and not to be in shutting down period.

IGVs preferably can be 3 to 4 deg less than full load (base load).

It was the problem of fogging with some DLN systems. But in DLN 2.6 we did not face this
problem.

However it was recommended by GE to reduce the load. It might be mentioned in your GE

manual also to whether do the water wash at reduced load or at base load.