Overview of Combined Cycle Turbine Technology: Matthew Esper, Bsme '06 - Uofm

OVERVIEW OF COMBINED CYCLE
TURBINE TECHNOLOGY
9/30/2014
MATTHEW ESPER, MECHANICAL ENGINEER

ENERGY
BSME ’06 – UofM
9/30/2014
AGENDA
• Who Is Black & Veatch?
• Overview of Traditional Thermal Cycles
• Overview of Combined Cycles
• Major Equipment of Combined Cycles
• Design Options for Combined Cycles
AGENDA
• Air Quality Control for Combined Cycles

• Review of Latest CTG in CC Technology
Options
• New Hire Responsibilities
• Questions
2
WHO IS
BLACK & VEATCH?
3
9/30/2014
WE’RE BUILDING A WORLD OF

DIFFERENCE. TOGETHER.
• Founded in 1915
• Global workforce of more than 10,000
WHO IS BLACK & VEATCH?
• Employee-owned corporation
• $3.6 billion in annual revenues in 2013
• More than 110 offices worldwide
• Completed projects in more than
100 countries
Black & Veatch conducts 7,000+ active projects

globally at any one time 4
9/30/2014
SOLVING THE WORLD’S COMPLEX

CHALLENGES IN EACH OF OUR MARKETS
Energy Water Telecommunications
Indonesia Hong Kong SAR California, USA
Security Management Consulting Environmental

Armenia Oklahoma, USA Scotland, UK
Using teamwork and collaboration we provide

sustainable and reliable solutions 5
9/30/2014
BLACK & VEATCH PROVIDES CONSTRUCTION

SERVICES TO THE ENERGY, WATER,
TELECOMMUNICATIONS AND FEDERAL MARKETS
Black & Veatch Overland Contracting Inc. Black & Veatch

Construction, Inc. (BVCI) (OCI) for open shop International (BVI) for
for union construction construction work outside the U.S.
We have extensive construction experience on

projects of complex size and scope throughout the
world 6
9/30/2014
THE RESULT IS A POSITION OF

INDUSTRY LEADERSHIP
ENR
1st – Top 20 in Telecommunications
1st – Top 25 in Fossil Fuel
3rd – Top 20 in Power
3rd – Top 20 in Transmission Lines and Aqueducts
Engineering News-Record 4th – Top 25 in Transmission and Distribution Plants

4th – Top 20 Contractors in Telecom
5th – Top 10 in Hydroplants
5th – Top 20 in Nuclear Plants
5th – Top 15 in Dams and Reservoirs
6th – Top 25 in Wastewater Treatment Plants
6th – Top 25 in Sanitary and Storm Sewers
6th – Top 20 in Water
8th – Top 20 in Sewerage and Solid Waste
9th – Top 20 Contractors in Power
10th – Top 20 in Water Treatment, Desalination Plants
11th – Top 50 Contractors Working Abroad
12th – Top 25 in Refineries and Petrochemical Plants
16th – Top 500 Design Firms
CENTURION 2nd – Top 100 Federal Contractors

Architectural & Engineering Services
RESEARCH SOLUTIONS
7
9/30/2014
BLACK & VEATCH HAS REGIONAL OFFICES

THROUGHOUT THE UNITED STATES
Arizona
California
Colorado
Delaware
District of Columbia
Florida
Georgia
Illinois
Indiana
Kansas
Kentucky
Louisiana
Maryland
Massachusetts
Michigan
Minnesota
Missouri
Nebraska
Nevada
New Jersey
New York
North Carolina
Ohio
Oregon
Pennsylvania
South Carolina Project offices are not included.
Texas
Virginia
Washington 8
9/30/2014
OUR GLOBAL PRESENCE ALLOWS US TO

APPLY GLOBAL EXPERTISE LOCALLY
Afghanistan Georgia Oman Taiwan

Armenia Hong Kong Palestine Thailand
Australia India Philippines Turkey
Azerbaijan Indonesia Puerto Rico Ukraine
Bahrain Kuwait Russia United Arab Emirates (UAE)
Canada Kazakhstan Saudi Arabia United Kingdom
Chile Malaysia Singapore United States
China Mexico South Africa Vietnam
Czech Republic Netherlands
9
9/30/2014
ANN ARBOR OFFICE OVERVIEW

• Michigan Business Began in 1980
• Ann Arbor Office Opened in 1988
• 260 Skilled Personnel
• Coal Plants
• Gas Turbines
• Combined Cycle
• Gasification / IGCC
• Renewables
• AQCS
• Energy Services
• Power Delivery
• Substations
10
9/30/2014
WE UNDERSTAND THE ENTIRE LIFE CYCLE

OF A POWER PLANT
Preliminary Select Major Detailed Cost Detailed Project Outage
Feasibility Schedules Equipment Estimates Engineering Completion Management
Study Planning
Construction /
Licensing / Systems Project Soils Construction Optimization
Permitting Analysis Schedule Testing Management
Market Permitting Monte Carlo Arrangement Project Startup Monitoring / Maintenance

Assessment Support Analysis Drawings Planning & Diagnostics & Outage
Controls Services
Plant Preliminary Operator Training
System
Commercial Retirement /
Configuration Cost Definitions
Contracting Procurement Decommissioning
Study Estimates
Strategies
Feasibility / Conceptual / Definition Project

Initial Engineering Execution Operations
Engineering
11
9/30/2014
B&V ENERGY – ANN ARBOR PROJECTS
Dallman • Coal Plants

Grayling
• Gasification / IGCC
• Biomass
• Carbon Capture
• Pre-combustion
• Post-combustion
• Gas Turbines
• Combined Cycle
Mesquite • Traditional HRSG
Gateway
• Solar Thermal
Hybrid
• Nuclear
• AQCS
• Wind
Black & Veatch has been involved in more megawatts of power

generation than any other company: 121,000+ MW worldwide 12
9/30/2014
TYPES OF POWER PLANTS

OVERVIEW OF COMBINED CYCLE TURBINE TECHNOLOGY
• Simple Cycle Combustion Turbine (Brayton Cycle)

• Coal Fired Thermal Plant (Rankine Cycle)
• Combined Cycle Plant (Brayton/Rankine)
• Cogeneration Plant
13
9/30/2014
TRADITIONAL COAL FIRED POWER PLANT

(LOW SULFUR COAL BASIS)
14
9/30/2014
CWLP DALLMAN UNIT 4 (COMMERCIAL OPERATION FALL 2009)

Unit 4 – 200 MW Net with Pulverized Coal Boiler
15
9/30/2014
SIMPLIFIED COMBINED CYCLE POWER PLANT

COMBINATION OF BRAYTON (GAS) AND RANKINE (STEAM) CYCLES
Stack
Air Inlet
Heat Recovery Steam Generator
Turbine
Compressor Section
Section
Fuel
Combustion
Turbine
Electric Substation
Generator
Electric
Steam Generator
Turbine
Condenser
Cooling Tower
16
CYCLE DIAGRAMS
9/30/2014
17
9/30/2014
MESQUITE GENERATING STATION (COMMERCIAL OP. 2003)

1250 MW Net with Natural Gas Fired Combustion Turbines and Duct Burners
18
9/30/2014
GATEWAY GENERATING STATION (COMMERCIAL OP. 2009)

600 MW Net with Natural Gas Fired Combustion Turbines, Duct Burners, Chillers
19
9/30/2014
MAJOR EQUIPMENT OF COMBINED CYCLES

Combustion Turbines
Heat Recovery Steam Generators
Steam Turbines
20
9/30/2014
COMBUSTION TURBINES
• Aeroderivatives are generally utilized for simple cycle peaking due to their
high simple cycle efficiency and low exhaust gas temperature
• New combined cycles generally utilize F, G, H, or J Class heavy duty frame
type CTGs
• F, G, H and J Class CTGs have axial exhaust and cold end drives
• F Class utilize compressor air for cooling hot components (ie, turbine blades
and transition pieces)
• G and J Class machines (MHI) utilize steam cooling (exception is M501GAC)
• Current H Class machines (GE and Siemens) do not utilize steam cooling, air
cooled
PARAMETER F CLASS G CLASS H and J CLASS
TURBINE INLET 1400 C / 2552 F 1500 C / 2732 F 1600 C / 2912 F

TEMPERATURE
(approximate)
21
9/30/2014
COMBUSTION TURBINES – TURBINE INLET TEMP

(TFIRE)
22
9/30/2014
COMBUSTION TURBINES
COMBUSTION TURBINE
CANS EXHAUST
TURBINE
COMPRESSOR SECTION
SECTION 23
9/30/2014
HISTORICAL PRIME MOVERS

F Class
CF
E Class Primary Suppliers
• ABB
AERO • GE
• Westinghouse
• Siemens V-Class
Early Frame
50 100 150 200

MW
1980’s to 2000’s, we saw 4 primary classes of
engines serving the U.S. market 24
9/30/2014
TODAY’S CT CHOICES
MPS J
GE 7HA.02 Series
Siemens H
MPS G
GE 7HA.01
Alstom
CF
Siemens F5
GE 7F.05
LMS 100
LM6000
100 150 200 250 300

MW
OEMS have filled in the MW gaps, increased MW
and improved efficiency 25
9/30/2014
TODAY’S CT PRODUCT LINE (>850 MMBTU/HR)

Nominal
CT CO2, CC CO2
CT MODEL MW 2x1
Efficiency lb/MWh Efficiency lb/MWh
CC MW
MPS J 327 41% 1,090 943 61.7% 724
GE 7HA.02 330 41.4% 1,079 976 61.2% 729
MPS GAC 276 39.8% 1,122 826 59.6% 750
GE 7HA.01 275 41.4% 1079 813 61.2% 729
Siemens H 274 40% 1,117 810 60.0% 745
Siemens F5EE 232 38.8% 1,152 690 58.6% 770
Alstom GT24 230 40% 1,117 664 58.4% 765
GE 7F.05 227 39.3% 1,136 688 59.5% 752
NSPS = 1000 lb/MWh for Larger CTs 26

9/30/2014
TODAY’S CT PRODUCT LINE

Combined cycle efficiency > 61% 27

9/30/2014
HEAT RECOVERY STEAM GENERATORS

• HRSGs are large air-to-water & steam heat exchangers

• Tube bundles include superheater, reheater, evaporator, and
economizer sections
28
9/30/2014
HEAT RECOVERY STEAM GENERATOR (HRSG)

Stack
Steam Drum
Outlet Duct
Internal Insulation
and Lagging
Inlet Ducts
Expansion Joint
Economizer Section
Downcomer
Evaporator
Section
Internal Superheater
Expansion Structural Section
Joint Steel
29
9/30/2014
HEAT RECOVERY STEAM GENERATOR ERECTION

30
9/30/2014

31
9/30/2014

Heat Transfer Module

(Tube Bundle)
Placement
Each bundle may have 12

or more tube rows
Tube to Header
Welds
32
9/30/2014
STEAM TURBINES
• Startup (warm up) time requirements vary and play significant

factor in combined cycle startup times
• The steam turbine can be purchased with
the combustion turbine or can be purchased
separately
• Possible suppliers include: General Electric,
Siemens, Toshiba, Mitsubishi, Alstom,
Hitachi
33
9/30/2014
DESIGN OPTIONS FOR COMBINED CYCLES

• HRSG Duct Burners for Raising STG Power

• Inlet Air Cooling (Evaporative or Chillers)
• Fuel Gas Heating
• Startup Time Considerations
34
9/30/2014
HRSG DUCT BURNERS

• Duct firing raises steam turbine power output

• Utilized when grid electrical demand is high
• Duct burner sizing depends on the Customers
requirements
• Heavy Duct Firing = Duct Burner Exit Temperature 1500
to 1600 F
• Heavier duct firing results in a greater efficiency penalty
35
9/30/2014
TYPICAL COMBINED CYCLE DESIGN –

DUCT BURNERS ON
Design Features:
2 CTGs x 1 STG
Combustion Turbines
GE 7FA.04*
3 Pressure Reheat
Includes Duct Burners

for 43 MW or 22%
Output Boost
for Steam Turbine
Fired Condition
Light Duct Firing
36
9/30/2014
TYPICAL COMBINED CYCLE DESIGN –

DUCT BURNERS OFF
Design Features:
2 CTGs x 1 STG
Combustion Turbines
GE 7FA.04*
3 Pressure Reheat
Includes Duct Burners

for 43 MW or 22%
Output Boost
for Steam Turbine
Unfired Condition
37
9/30/2014
OTHER DUCT FIRED 2X1 7FA DESIGN EXAMPLES

Project Alpha Alpha Bravo Bravo Charlie Charlie
Heat Rejection Once Through Air Cooled Condenser Mechanical Tower
Ambient Temperature F 47 47 101 101 95 95

Duct Burners Fired Unfired Fired Unfired Fired Unfired
Exit Temperature F 1164 1297 1511
Steam Turbine
Output MW 238.6 195.9 233.6 168.5 317.2 181.4
Power Increase MW 42.7 65.1 135.8
Power Increase % 22 39 75
Throttle Pressure PSIA 1901 1523 1950 1361 1905 990
Plant Net Output MW 581.6 540.2 501.6 436.5 609.2 479.4
Power Increase MW 41.4 65.1 129.8
Net Efficiency - LHV % 55.5 56.0 51.3 52.4 51.2 54.9
 Three Separate Project Examples  Note Ambient Temperature and Heat

Rejection Differences
 Same CTG, Different Cycle Designs
 Note Change in STG Throttle Pressure from
 Light Firing Increased STG Output 22% Unfired to Fired Condition
 Heavy Firing Increased STG Output 75%  Sliding STG Inlet Pressure
38
9/30/2014
INLET AIR COOLING (EVAPORATIVE TYPE)

• Combustion turbine inlet air cooling raises CTG

power output
• Evaporative coolers are relatively inexpensive, but
consume water
• Incorporated into the inlet air filter housing by the
CTG OEM
• Evaporative coolers are most effective in arid
climates, but are frequently included in plant
designs for all types of climates
39
9/30/2014
INLET AIR COOLING (CHILLER TYPE)

• Chillers are expensive, but yield greater CTG power output

increase
• Typically sized to reduce CTG inlet air temperature to 50 F from
some specific ambient condition
• Typically water is a byproduct, condensed from the ambient air,
and can be utilized elsewhere within the power plant
• The chilling heat transfer coil is integrated into the inlet air filter
housing by the CTG OEM
• Chilling system designs vary, particularly the fluid passing through
the coil that chills the ambient air (typically chilled water)
• Refrigerant types: anhydrous ammonia, R-123, etc
• Unlike evaporative coolers, inlet air chillers yield an efficiency
penalty
40
9/30/2014
INLET AIR CHILLED 2X1 7FA DESIGN EXAMPLE

Project Bravo Bravo Bravo Bravo
Heat Rejection Air Cooled Condenser
Ambient Temperature F 101 101 101 101
Chiller Status On Off On Off
Duct Burners Fired Fired Unfired Unfired
Exit Temperature F 1238 1297
Steam Turbine
Output MW 234.4 233.6 176.9 168.5
Throttle Pressure PSIA 1950 1950 1424 1361
Plant Net Output MW 553.9 501.6 496.4 436.5
Power Increase MW 52.3 59.9
Net Efficiency - LHV % 51.0 51.3 51.8 52.4
 Chiller primarily increases CTG power  STG power increase is due to increased CTG
exhaust energy to the HRSG
 STG power is increased if it is not already at
maximum output due to duct firing  Chiller operation yields slight efficiency
penalty
 If STG was already fired to the maximum,
duct firing is reduced
41
9/30/2014
FUEL GAS HEATING

• Fuel gas heating increases the efficiency of the combined

cycle
• Low grade heat from the HRSG is used to pre-heat the fuel
gas which improves combustion turbine heat rate
• The heated fuel gas temperature will depend on the CTG
OEM
• Values between 280 F and 365 F are common
• The temperature must be controlled to a stable set point
or the CTG will run back or trip
• Typically feed water from either the LP drum (280 F) or the
IP economizer exit (365 F) is utilized to heat the fuel gas
42
9/30/2014
STARTUP TIME CONSIDERATIONS

Startup times are an increasingly important consideration for

combined cycles due to the following:
• Startup emissions are often limited by air permits

• Agencies understand startup emissions can be minimized
• Faster startups consume less fuel and thus save the Owner
money
• Fast startups allow the operator to hit higher outputs faster,
increasing revenue for merchant generators
• Combined cycles will increasingly be required to start and/or
change loads quickly as wind turbine farm output and/or solar
energy output to the grid varies
43
9/30/2014
CHANGING SYSTEM DYNAMICS

Impact of wind generation on power system load
• Wind is intermittent and is a major contributor during low load hours, but only
minimal during peak load hours
• Wind generation requires a generation mix with more operational flexibility to
serve the net load
Addition of wind
Wind generation has generation: Net Load
small (but not zero) Duration Curve becomes
more steep Hydro
impact on peak load
Gas GT
Peaking
Peaking
Generation
Generation
System Load
Mid-Merit Gas
Mid-Merit CCGT
Generation
Generation
Base Load
Generation Base Load
Generation
Hours of Operation / Year

Wind generation has
System Load without wind major impact on low and
minimum load conditions Clean 44
Net System Load with wind
Coal
9/30/2014
AIR QUALITY CONTROL FOR COMBINED

CYCLES
New large combined cycles in the United States typically include

the following air quality control equipment and features:
• Dry Low NOx burners for the CTG
• Selective Catalytic Reduction (SCR) system in the HRSG for NOx
reduction
• Ammonia injection for the HRSGs SCR
• Carbon Monoxide (CO) catalyst in the HRSG for CO and VOC
reduction
45
9/30/2014
HOW DOES AN ENTRY-LEVEL MECHANICAL ENGINEER

GET INVOLVED?
System Engineer Pipe Stress Engineer

• Development of system P&ID’s • Modeling of piping systems
• Service/Potable Water • Pipe materials, temperatures &
• Station Air pressures
• Compressed Gases • Model supports
• Wastewater Collection • Thermal growth
• System and equipment sizing • Wind & seismic activity
calculations • Verify design meets equipment
• Centrifugal/Vertical Sump Pumps and code allowables
• Air Compressors/Dryers • Pipe support detail drawings
• System Piping • Anchors, rod hangers, springs,
• Development of technical struts & shock absorbers
specifications for equipment
• Pumps/Compressors
• Valves/Miscellaneous Piping
Devices
46
WHAT IS A P&ID?
9/30/2014
47
WHAT IS A PIPING ISOMETRIC?

9/30/2014
48
PIPE STRESS ANALYSIS

9/30/2014
49
9/30/2014
CAREER RELEVANT COURSEWORK

System Engineer Pipe Stress Engineer

• Major Required: • Major Required:
• Thermodynamics • Materials Science & Engineering
• Fluid Mechanics • Statics
• Heat Transfer
• Electives
• Electives • Intermediate Mechanics of
• Intro to Combustion Deformable Solids
• Energy Conversion • Computer Aided Design of
• Computer Assisted Design of Structures
Thermal Systems • Finite Element Analysis
• Design of Alternative Energy
Systems
50

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OVERVIEW OF COMBINED CYCLE

MATTHEW ESPER, MECHANICAL ENGINEER

• Air Quality Control for Combined Cycles

WE’RE BUILDING A WORLD OF

Black & Veatch conducts 7,000+ active projects

SOLVING THE WORLD’S COMPLEX

Security Management Consulting Environmental

Using teamwork and collaboration we provide

BLACK & VEATCH PROVIDES CONSTRUCTION

Black & Veatch Overland Contracting Inc. Black & Veatch

We have extensive construction experience on

THE RESULT IS A POSITION OF

Engineering News-Record 4th – Top 25 in Transmission and Distribution Plants

CENTURION 2nd – Top 100 Federal Contractors

BLACK & VEATCH HAS REGIONAL OFFICES

OUR GLOBAL PRESENCE ALLOWS US TO

Afghanistan Georgia Oman Taiwan

ANN ARBOR OFFICE OVERVIEW

WE UNDERSTAND THE ENTIRE LIFE CYCLE

Market Permitting Monte Carlo Arrangement Project Startup Monitoring / Maintenance

Feasibility / Conceptual / Definition Project

B&V ENERGY – ANN ARBOR PROJECTS

Dallman • Coal Plants

Black & Veatch has been involved in more megawatts of power

TYPES OF POWER PLANTS

• Simple Cycle Combustion Turbine (Brayton Cycle)

TRADITIONAL COAL FIRED POWER PLANT

CWLP DALLMAN UNIT 4 (COMMERCIAL OPERATION FALL 2009)

SIMPLIFIED COMBINED CYCLE POWER PLANT

Heat Recovery Steam Generator

MESQUITE GENERATING STATION (COMMERCIAL OP. 2003)

GATEWAY GENERATING STATION (COMMERCIAL OP. 2009)

MAJOR EQUIPMENT OF COMBINED CYCLES

Heat Recovery Steam Generators

TURBINE INLET 1400 C / 2552 F 1500 C / 2732 F 1600 C / 2912 F

COMBUSTION TURBINES – TURBINE INLET TEMP

HISTORICAL PRIME MOVERS

50 100 150 200

100 150 200 250 300

TODAY’S CT PRODUCT LINE (>850 MMBTU/HR)

NSPS = 1000 lb/MWh for Larger CTs 26

TODAY’S CT PRODUCT LINE

Combined cycle efficiency > 61% 27

HEAT RECOVERY STEAM GENERATORS

• HRSGs are large air-to-water & steam heat exchangers

HEAT RECOVERY STEAM GENERATOR (HRSG)

HEAT RECOVERY STEAM GENERATOR ERECTION

HEAT RECOVERY STEAM GENERATOR ERECTION

HEAT RECOVERY STEAM GENERATOR ERECTION

Heat Transfer Module

Each bundle may have 12

• Startup (warm up) time requirements vary and play significant

DESIGN OPTIONS FOR COMBINED CYCLES

• HRSG Duct Burners for Raising STG Power

HRSG DUCT BURNERS

• Duct firing raises steam turbine power output

TYPICAL COMBINED CYCLE DESIGN –

Includes Duct Burners

Light Duct Firing

TYPICAL COMBINED CYCLE DESIGN –

Includes Duct Burners

OTHER DUCT FIRED 2X1 7FA DESIGN EXAMPLES

Project Alpha Alpha Bravo Bravo Charlie Charlie