Gas Turbine Technologies for Electric Generation

by

Rob Shepard, P.E.

www.Neel-Schaffer.com rob.shepard@neel-schaffer.com

Gas Turbine Basics

Gas Turbines

Types How They Work Applications Components of Plant Flow Paths Operation

Gas Turbine Applications

Simple Cycle Combined Cycle Cogeneration

Types of Gas Turbine Plants

Simple Cycle

Operate When Demand is High Peak Demand Operate for Short / Variable Times Designed for Quick Start-Up Not designed to be Efficient but Reliable

Not Cost Effective to Build for Efficiency

Combined Cycle

Operate for Peak and Economic Dispatch Designed for Quick Start-Up Designed to Efficient, Cost-Effective Operation Typically Has Ability to Operate in SC Mode

Principles of Operation

Open Cycle

Also referred to as simple cycle)

The energy contained in a flowing ideal gas is the sum of enthalpy and kinetic energy. Pressurized gas can store or release energy. As it expands the pressure is converted to kinetic energy.
Link to picture

Brayton Cycle Gas Turbine Cycle

Thermodynamic Fundamentals

Pressure Ratio & CT Components

Combustion or Gas Turbine

Principles of Operation
Compressor As air flows into the compressor, energy is transferred from its rotating blades to the air. Pressure and temperature of the air increase. Most compressors operate in the range of 75% to 85% efficiency. Combustor The purpose of the combustor is to increase the energy stored in the compressor exhaust by raising its temperature. Turbine The turbine acts like the compressor in reverse with respect to energy transformation. Most turbines operate in the range of 80% to 90% efficiency.

Principles of Operation
Overall Energy Transformations (Thermal Efficiency)

Useful Work = Energy released in turbine minus energy absorbed by compressor.

The compressor requires typically approximately 50% of the energy released by the turbine.

Overall Thermal Efficiency = Useful Work/Fuel Chemical Energy *100

Typical overall thermal efficiencies of a combustion turbine are 20% - 40%.

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Gas Turbine Applications

Simple Cycle

Link to picture
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Simple Cycle Power Plant Westinghouse 501D5 340 MW

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Combined Cycle Power Plant

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Combined Cycle Plant Design

GT PRO 13.0 Drew Wozniak 12.54 p 90 T 30 %RH 944 m 4327 ft elev. Net Power 95959 kW LHV Heat Rate 7705 BTU/kWh 1X GE 6581B Fogger 4.717 m 12.39 p 68 T 948.7 m 30813 kW Natural gas 18.58 m LHV 369671 kBTU/h 77 T 149.2 p 684 T 143.2 p 2072 T 967.3 m 2 X GT 12.93 p 1034 T 1934.6 M 73.85 %N2 13.53 %O2 3.233 %CO2+SO2 8.497 %H2O 0.8894 %Ar

33781 kW

122 T 292.6 M 122 T 17.19 p 220 T

96 T

850 p 950 T 248.6 M 1.694 p 120 T 222.1 M 0.1296 M 26.36 M

292.6 M 29.65 M 29.58 M

183 p 375 T 70 M V4 6.89 M V8 6.89 M LPB 268 T 1934.6 M 17.19 p 220 T 29.65 M 268 326 203.6 p 373 T 292.6 M 419 203.6 p 924.2 p 383 T 472 T 36.75 M 251.1 M 481 534 199.7 p 910.5 p 460 T 523 T 36.75 M 251.1 M 538 568 195.8 p 910.5 p 500 T 533 T 36.75 M 248.6 M 569 IPE2 IPB HPE2 IPS1 HPE3 IPS2 HPB1 p[psia], T[F], M[kpph], Steam Properties: Thermoflow - STQUIK 1512 10-13-2004 23:27:31 file=C:\Tflow13\MYFILES\3P 0 70.gtp

195.8 p 597 T

897

879.8 p 954 T

120 T

FW

HPS3 1031 T 1934.6 M 879.8 p 954 T 248.6 M 1031 Natural gas 0M

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Gas Turbine Components Compressor Combustor - Turbine

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Gas Turbine Components & Systems (contd)

Combustion System

Exhaust System

Silo, Cannular, Annular Water, Steam, DLN

Simple Cycle Stack Transition to HRSG Open-Air cooled TEWAC Hydrogen Cooled Diesel Motor Static
Paper Towel thru compressor

Turbine

Generator

Multiple Shaft, Single Shaft Number of Stages Material and Manufacturing Processes

Starting Systems

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Combustion Turbine Fuels

Conventional Fuels

Natural Gas Liquid Fuel Oil Crude Oil Refinery Gas Propane

Nonconventional Fuels

Synthetic Fuels

Chemical Process Physical Process

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GE Combustion Turbine Comparisons

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Gas Turbine Types

Advanced Heavy-Duty Units Advanced Aeroderivative Units

Parameter
Capital Cost, $/kW Capacity, MW Efficiency Plan Area Size Maintenance Requirements Technological Development

Heavy Duty Aero-Derivative

Lower 10 - 330 Lower Larger Lower Lower Higher 5 100 Higher Smaller Higher Higher

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Gas Turbine Major Sections

Air Inlet Compressor Combustion System Turbine Exhaust Support Systems

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Gas Turbine Barrier Inlet Filter Systems

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Gas Turbine Pulse Inlet Filter System

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Inlet Guide Vanes

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Inlet Guide Vanes

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Gas Turbine Compressor Rotor Assembly

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6B Gas Turbine

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Gas Turbine Cut Away Side View

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Gas Turbine Combustor Arrangement

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Frame 5 GT

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GE LM2500 Aeroderivative Gas Turbine

Compressor Turbine Section

Power Turbine Section

Compressor

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FT4 Gas Turbine

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FT4 Gas Turbine Gas Generator (Compressor)

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FT4 Gas Turbine Gas Generator (Compressor)

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FT4 Gas Turbine Free Turbine

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FT4 Gas Turbine Free Turbine Gas Path

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FT4 Gas Generator Performance

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FT4 Free Turbine Performance

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Aeroderivative Versus Heavy Duty Combustion Turbines

Aeroderivatives

Higher Pressure Ratios and Firing Temperatures Result in Higher Power Output per Pound of Air Flow Smaller Chilling/Cooling Systems Required Compressor Inlet Temperature Has a Greater Impact on Output and Heat Rate Benefits of Chilling/Cooling Systems are More Pronounced

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Typical Simple Cycle CT Plant Components

Prime Mover (Combustion Turbine) Fuel Supply & Preparation Emissions Control Equipment Generator Electrical Switchgear Generator Step Up Transformer Starting System (Combustion Turbines) Auxiliary Cooling Fire Protection Lubrication System

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Typical Peaking Plant Components

Lube Oil System

GSU

Generator

Switchgear / MCC
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Starting Engine

Fire Protection

Combining the Brayton and Rankine Cycles

Gas Turbine Exhaust used as the heat source for the Steam Turbine cycle Utilizes the major efficiency loss from the Brayton cycle Advantages:

Relatively short cycle to design, construct & commission Higher overall efficiency Good cycling capabilities Fast starting and loading Lower installed costs No issues with ash disposal or coal storage High fuel costs Uncertain long term fuel source Output dependent on ambient temperature

Disadvantages

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How does a Combined Cycle Plant Work?

Picture courtesy of Nooter/Eriksen

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Combined Cycle Heat Balance

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Combined Cycles Today

Plant Efficiency ~ 58-60 percent

Biggest losses are mechanical input to the compressor and heat in the exhaust
Typically 50% of the gas turbine output More with duct-firing up to 750 MW for 3 on 1 configuration Up to 520 MW for 2 on 1 configuration

Steam Turbine output

Net Plant Output (Using Frame size gas turbines)

Construction time about 24 months Engineering time 80k to 130k labor hours Engineering duration about 12 months Capital Cost ($900-$1100/kW) Two (2) versus Three (3) Pressure Designs

Larger capacity units utilize the additional drums to gain efficiency at the expense of higher capital costs

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Combined Cycle Efficiency

Simple cycle efficiency (max ~ 44%*) Combined cycle efficiency (max ~58-60%*) Correlating Efficiency to Heat Rate (British Units)

h= 3412/(Heat Rate) Simple cycle Combined cycle h= 3600/(Heat Rate) Simple cycle Combined cycle

--> 3412/h = Heat Rate* 3412/.44 = 7,757 Btu/Kwh* 3412/.58 = 5,884 Btu/Kwh* --> 3600/h = Heat Rate* 3600/.44 = 8,182 KJ/Kwh* 3600/.58 = 6,207 KJ/Kwh*

Correlating Efficiency to Heat Rate (SI Units)

Practical Values

HHV basis, net output basis Simple cycle 7FA (new and clean) 10,860 Btu/Kwh (11,457 KJ/Kwh) Combined cycle 2x1 7FA (new and clean) 6,218 Btu/Kwh (6,560 KJ/Kwh)
*Gross LHV basis

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Gas Turbine Generator Performance

Factors that Influence Performance

Fuel Type, Composition, and Heating Value Load (Base, Peak, or Part) Compressor Inlet Temperature Atmospheric Pressure Inlet Pressure Drop

Varies significantly with types of air cleaning/cooling Affected by addition of HRSG, SCR, CO catalysts Used for either power augmentation or NOx control

Exhaust Pressure Drop

Steam or Water Injection Rate

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Relative Humidity

Altitude Correction

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Humidity Correction

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Cogeneration Plant

A Cogeneration Plant

Power generation facility that also provides thermal energy (steam) to a thermal host. paper mills, chemical plants, refineries, etc potentially any user that uses large quantities of steam on a continuous basis. Require both steam and electrical power

Typical thermal hosts

Good applications for combined cycle plants

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Major Combined Cycle Plant Equipment

Combustion Turbine (CT/CTG) Steam Generator (Boiler/HRSG) Steam Turbine (ST/STG) Heat Rejection Equipment Air Quality Control System (AQCS) Equipment Electrical Equipment

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Heat Recovery Steam Generator (HRSG)

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Steam Turbine

GE D11

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Heat Rejection Equipment - Condenser

Same Function as discussed earlier in Session 9

Usually utilizes a cooling tower to reject heat to the atmosphere Rarely uses once through cooling (retrofit applications or ocean)

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Questions?

Rob Shepard Neel-Schaffer, Inc. www.Neel-Schaffer.com rob.shepard@neel-schaffer.com

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