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CCGT AT A GLANCE 27th Dec 2011 By- K. S. YADAV
GAS TURBINE Principle of working:- Works on Braton Cycle with two nos. Adiabatic processes of compression & expansion in compressor and turbine respectively and Two processes at constant pressure i.e. Heat addition in combustion chambers and exhaust at constant pressure.
GAS TURBINE Principle of Operation:- Rotor is initially brought to speed by starting means. Atmospheric air is drawn into the compressor and raised to static pressure more than the atmospheric. This high pressure air is allowed to through continuous flow Combustion Chambers where fuel is ignited with high voltage igniters. The product of combustion is expanded in the turbine which cause it to spin and thus applying a torque to the driven accessories i.e. Generator
WORKING PRINCIPLE BRATON CYCLE
BRAYTON CYCLE
Developed by Georg Brayton (1832 -1890) Heat is added and discharged at constant pressure Applied in Gas Turbines (GT) (Combustion Turbines)
BRAYTON CYCLE
Efficiency (K-1)/K
η = 1 – 1/ rp where
rp = compressor pressure ratio = p2/p1
k = gas constant
The Actual Thermodynamic cycle For all practical reasons the actual thermal efficiency will depend on
Pressure ratio Turbine inlet Temp Compressor inlet temp Efficiency of Compressor and Turbine
PRINCIPLE
FLANGE TO FLANGE VIEW OF A GAS TURBINE
GT MODELS AND RATING Model ISO Rating (kw) ISO Efficiency (%) (1) MS1002 5070 24.5 (2) MS3142(J) 10450 25.6 (3) PG5371(PA) 26300 28.5 (4) PG6581(B) 42100 32.0 (5) PG6111(FA) 75900 35.0 (6) PG9171(E) 123400 33.8 (7) PG9231(EC) 169200 34.9 (8) PG9351(FA) 255600 36.5 (9) PG9551(H) 380,000 Note: ISO output is : 15 deg C, 60% RH, Zero MSL, Gas fuel and standard Inlet/Exh. Pr. drops
GE Generator Drive Product Line Model
Fuel
ISO Base Rating(kW)
Heat Rate (Btu/kWh)
Heat Rate (kJ/kWh)
Exhaust Flow (lb/hr) x10-3
Exhaust Flow (kg/hr) x10-3
Exhaust Temp (degrees F)
Exhaust Temp (degrees C)
Pressure Ratio
PG5371 (PA)
Gas Dist
26,070 25,570
12,060 12,180
12,721 12,847
985 998
446 448
905 906
485 486
10.6 10.6
PG6581 (B)
Gas Dist
42,100 41,160
10,640 10,730
11,223 11,318
1158 1161
525 526
1010 1011
543 544
12.2 12.1
PG6101 (FA)
Gas Dist
69,430 74,090
10,040 10,680
10,526 10,527
1638 1704
742 772
1101 1079
594 582
14.6 15.0
PG7121 (EA)
Gas Dist
84,360 87,220
10,480 10,950
11,054 11,550
2361 2413
1070 1093
998 993.
536 537
12.7 12.9
PG7241 (FA)
Gas Dist
171,700 183,800
9,360 9,965.
9,873 10,511
3543 3691
1605 1672
1119 1095
604 591
15.7 16.2
PG7251 (FB)
Gas Dist
184,400 177,700
9,245 9,975
9,752 10,522
3561 3703
1613 1677
1154 1057
623 569
18.4 18.7
PG9171 (E)
Gas Dist
122,500 127,300
10,140 10,620
10,696 11,202
3275 3355
1484 1520
1009 1003
543 539
12.6 12.9
PG9231 (EC)
Gas Dist
169,200 179,800
9,770 10,360
10,305 10,928
4131 4291
1871 1944
1034 1017
557 547
14.4 14.8
PG9351 (FA)
Gas Dist
255,600 268,000
9,250 9,920
9,757 10,464
5118 5337
2318 2418
1127 1106
608 597
15.3 15.8
STEAM TURBINE The Steam Turbine is Steam Driven rotary engine that converts Heat Energy of Steam to Mechanical Energy at Shaft.
STEAM TURBINE Working Principle – Steam Turbine works on Rankin Thermodynamic Cycle
RANKINE CYCLE
Scottish engineer William Rankine (18201872) developed a theory of steam cycles Heat is added in a water boiler, where the water becomes steam Steam is fed to a steam turbine, which generates mechanical energy After turbine the steam becomes water again in a condenser
RANKINE CYCLE
The efficiency varies from 20 % in small subcritical steam turbines to 45 % in large double reaheat supercritical steam turbines The rankine cycle is ideal for solid fuel (coal, wood) power plants
RANKINE CYCLE
Steam turbines are most sold machines for power plants as measured in output They are used in coal fired, nuclear and combined cycle power plants Coal and nuclear plants generate about 50 % of world electricity
STEAM TURBINE 1-2 2-3 3-4 4-5 5-6 6-1
–Exp. in Steam ST – Heat Rej. In Cond. – Compression in BFP – Heat addition in Eco – Heat addition in Blr – Heat addition in SH
Construction of steam turbines
1 – steam pipeline 2 – inlet control valve 3 – nozzle chamber 4 – nozzle-box 5 – outlet 6 – stator 7 – blade carrier 8 – casing
9 – rotor disc 10 – rotor 11 – journal bearing 13 – thrust bearing 14 – generator rotor 15 – coupling 16 – labyrinth packing 19 – steam bleeding (extraction)
21 – bearing pedestal 22 – safety governor 23 – main oil pump 24 – centrifugal governor 25 – turning gear 29 – control stage impulse blading
Construction of steam turbines
Construction of steam turbines
COMBINED CYCLE In combined cycle high temperature exhaust gases of gas turbine are made to through HRSG to generate steam and further this steam is used in steam turbine for power production. Thus cycle efficiency is increased by about 50 %
COMBINED CYCLE
COMBINED CYCLE
Combines a gas turbine (Brayton cycle) and steam turbine (Rankine Cycle) About 66 % of power is generated in gas turbine and 34 % in steam turbine Efficiency of GTCC plant is typically 1.5 times the efficiency of the single cycle gas turbine plant
GAS TURBINE WITH HRSG
HRSG
Combined Cycle Power Plant WHRB 15% Exhaust gas Gas Turbine
Steam G G
33%
Air
Condensor
Fuel 100% Input
16% Steam Turbine
36%
Combined Module Cycle Configurations Fuel 255 MW G Steam
Air
GT-1
276 MW
Exhaust gas
G
Air GT-2
Exhaust gas
ST-1
G 255 MW
Fuel
2 X 255 + 1 X 276 = 786 MW
Combined Cycle Module Configurations Fuel G
Air
GT-1
Exhaust gas
Fuel
Steam G G
Air
GT-2
Exhaust gas ST-1
Fuel G 3 X 140 + 1 X 230 = 650 MW
Air
GT-3
Exhaust gas
Combined Cycle Module Configurations Exhaust gas
Single Shaft Module
Steam
Gas Turbine
G
Steam Turbine Fuel
Air 250 MW GT + 140 MW ST = 390 MW
GAS TURBINE AUXILIARIES
STARTING MEANS- ENGINE/MOTOR/FC LUBE OIL PUMPS - MOP - AOP - EOP HYDRAULIC PUMPS- MHOP - AHOP AGB COOLING WATER PUMP
GAS TURBINE AUXILIARIES BOOSTER COMPRESSOR ATOMIZING AIR COMPRESSOR FUEL GAS CONDITIONING SKID LP FUEL OIL PUMP HP FUEL OIL PUMP COMP. WASHING SKID STARTING CLUTCH
GAS TURBINE SYSTEMS AIR INLET SYSTEM COMPRESSION SYSTEM - AIR COMPRESSOR - VIGVs - STATOR BLADES - ROTOR BLADES - EGVs
INLET PLENUM
TURBINE FILTERS
TURBINE FILTERS
VIGVs
VIGVs
COMPRESSOR ROTOR
COMP. STATOR BLADES
COMP. ROTOR X- SECTION
GAS TURBINE SYSTEMS
COMBUSTION SYSTEM - FUEL NOZZLES - CLs - TPs - X- FIRE TUBES - SPARK PLUGS - FLAME SCANNERS
FUEL NOZZLE
FUEL NOZZLE
X- FIRE TUBES
COMBUSTION LINER
TRANSITION PIECE
SPARK PLUGS
FLAME SCANNER
GAS TURBINE SYSTEMS
EXPANSION - I, II, III STAGE NOZZLES - I, II, III STAGE BUCKETS - I, II, III STAGE SHROUDS - WHEEL SPACERS
U/H TURBINE VIEW
I STAGE BUCKETS
I STAGE NOZZLE
GAS TURBINE SYSTEMS
EXHAUST -EXHAUST DIFFS - EXHAUST THERCOUPLES
HRSG & STEAM TURBINE HRSG DIVERTER DAMPER ECONOMIZER FEED CONTROL STATION EVAPORATORS SUPER HEATERS MAIN STEAM STOP VALVE
STEAM TURBINE STEAM TURBINE – STEAM CONTROL & STOP VALVE HP TURBINE LP TURBINE CONDENSER SEALING STEAM SYSTEM VACUUM PUMP
STEAM TURBINE AUXILIARIES
STEAM CONTROL SYSTEM BARREN GEAR SEALING SYSTEM LUBRICATION SYSTEM CEPs BFPs AUX. COOLING WATER SYSTEM CONDENSER & COOLING SYSTEM
CONDENSER
COOLING TOWER
COOLING TOWER
COOLING TOWER
HRSG
TYPES OF STEAM TURBINES Based
on the steam expansion- Impulse Turbine - Reaction Turbine
TYPES OF STEAM TURBINES
TYPES OF STEAM TURBINES Based
on the direction of steam flow- Radial Flow Turbine - Axial Flow Turbine
TYPES OF STEAM TURBINES
TYPES OF STEAM TURBINES Based
on the no. of stages - Single Stage Turbine - Multi Stage Turbine
TYPES OF STEAM TURBINES
TYPES OF STEAM TURBINES Based
on the Power Utilization- Industrial Turbine - Transport Turbine
TYPES OF STEAM TURBINES
TYPES OF STEAM TURBINES
Based on the Exhaust Pressure - Condensing Turbine - Back pressure Turbine - Extraction Turbine
TYPES OF STEAM TURBINES
QUESTIONS ?
K. S YADAV Manager (M-I),PPCL
Cell - 09717694741 email- [email protected]
GAS TURBINE Principle of working:- Works on Braton Cycle with two nos. Adiabatic processes of compression & expansion in compressor and turbine respectively and Two processes at constant pressure i.e. Heat addition in combustion chambers and exhaust at constant pressure.
GAS TURBINE Principle of Operation:- Rotor is initially brought to speed by starting means. Atmospheric air is drawn into the compressor and raised to static pressure more than the atmospheric. This high pressure air is allowed to through continuous flow Combustion Chambers where fuel is ignited with high voltage igniters. The product of combustion is expanded in the turbine which cause it to spin and thus applying a torque to the driven accessories i.e. Generator
WORKING PRINCIPLE BRATON CYCLE
BRAYTON CYCLE
Developed by Georg Brayton (1832 -1890) Heat is added and discharged at constant pressure Applied in Gas Turbines (GT) (Combustion Turbines)
BRAYTON CYCLE
Efficiency (K-1)/K
η = 1 – 1/ rp where
rp = compressor pressure ratio = p2/p1
k = gas constant
The Actual Thermodynamic cycle For all practical reasons the actual thermal efficiency will depend on
Pressure ratio Turbine inlet Temp Compressor inlet temp Efficiency of Compressor and Turbine
PRINCIPLE
FLANGE TO FLANGE VIEW OF A GAS TURBINE
GT MODELS AND RATING Model ISO Rating (kw) ISO Efficiency (%) (1) MS1002 5070 24.5 (2) MS3142(J) 10450 25.6 (3) PG5371(PA) 26300 28.5 (4) PG6581(B) 42100 32.0 (5) PG6111(FA) 75900 35.0 (6) PG9171(E) 123400 33.8 (7) PG9231(EC) 169200 34.9 (8) PG9351(FA) 255600 36.5 (9) PG9551(H) 380,000 Note: ISO output is : 15 deg C, 60% RH, Zero MSL, Gas fuel and standard Inlet/Exh. Pr. drops
GE Generator Drive Product Line Model
Fuel
ISO Base Rating(kW)
Heat Rate (Btu/kWh)
Heat Rate (kJ/kWh)
Exhaust Flow (lb/hr) x10-3
Exhaust Flow (kg/hr) x10-3
Exhaust Temp (degrees F)
Exhaust Temp (degrees C)
Pressure Ratio
PG5371 (PA)
Gas Dist
26,070 25,570
12,060 12,180
12,721 12,847
985 998
446 448
905 906
485 486
10.6 10.6
PG6581 (B)
Gas Dist
42,100 41,160
10,640 10,730
11,223 11,318
1158 1161
525 526
1010 1011
543 544
12.2 12.1
PG6101 (FA)
Gas Dist
69,430 74,090
10,040 10,680
10,526 10,527
1638 1704
742 772
1101 1079
594 582
14.6 15.0
PG7121 (EA)
Gas Dist
84,360 87,220
10,480 10,950
11,054 11,550
2361 2413
1070 1093
998 993.
536 537
12.7 12.9
PG7241 (FA)
Gas Dist
171,700 183,800
9,360 9,965.
9,873 10,511
3543 3691
1605 1672
1119 1095
604 591
15.7 16.2
PG7251 (FB)
Gas Dist
184,400 177,700
9,245 9,975
9,752 10,522
3561 3703
1613 1677
1154 1057
623 569
18.4 18.7
PG9171 (E)
Gas Dist
122,500 127,300
10,140 10,620
10,696 11,202
3275 3355
1484 1520
1009 1003
543 539
12.6 12.9
PG9231 (EC)
Gas Dist
169,200 179,800
9,770 10,360
10,305 10,928
4131 4291
1871 1944
1034 1017
557 547
14.4 14.8
PG9351 (FA)
Gas Dist
255,600 268,000
9,250 9,920
9,757 10,464
5118 5337
2318 2418
1127 1106
608 597
15.3 15.8
STEAM TURBINE The Steam Turbine is Steam Driven rotary engine that converts Heat Energy of Steam to Mechanical Energy at Shaft.
STEAM TURBINE Working Principle – Steam Turbine works on Rankin Thermodynamic Cycle
RANKINE CYCLE
Scottish engineer William Rankine (18201872) developed a theory of steam cycles Heat is added in a water boiler, where the water becomes steam Steam is fed to a steam turbine, which generates mechanical energy After turbine the steam becomes water again in a condenser
RANKINE CYCLE
The efficiency varies from 20 % in small subcritical steam turbines to 45 % in large double reaheat supercritical steam turbines The rankine cycle is ideal for solid fuel (coal, wood) power plants
RANKINE CYCLE
Steam turbines are most sold machines for power plants as measured in output They are used in coal fired, nuclear and combined cycle power plants Coal and nuclear plants generate about 50 % of world electricity
STEAM TURBINE 1-2 2-3 3-4 4-5 5-6 6-1
–Exp. in Steam ST – Heat Rej. In Cond. – Compression in BFP – Heat addition in Eco – Heat addition in Blr – Heat addition in SH
Construction of steam turbines
1 – steam pipeline 2 – inlet control valve 3 – nozzle chamber 4 – nozzle-box 5 – outlet 6 – stator 7 – blade carrier 8 – casing
9 – rotor disc 10 – rotor 11 – journal bearing 13 – thrust bearing 14 – generator rotor 15 – coupling 16 – labyrinth packing 19 – steam bleeding (extraction)
21 – bearing pedestal 22 – safety governor 23 – main oil pump 24 – centrifugal governor 25 – turning gear 29 – control stage impulse blading
Construction of steam turbines
Construction of steam turbines
COMBINED CYCLE In combined cycle high temperature exhaust gases of gas turbine are made to through HRSG to generate steam and further this steam is used in steam turbine for power production. Thus cycle efficiency is increased by about 50 %
COMBINED CYCLE
COMBINED CYCLE
Combines a gas turbine (Brayton cycle) and steam turbine (Rankine Cycle) About 66 % of power is generated in gas turbine and 34 % in steam turbine Efficiency of GTCC plant is typically 1.5 times the efficiency of the single cycle gas turbine plant
GAS TURBINE WITH HRSG
HRSG
Combined Cycle Power Plant WHRB 15% Exhaust gas Gas Turbine
Steam G G
33%
Air
Condensor
Fuel 100% Input
16% Steam Turbine
36%
Combined Module Cycle Configurations Fuel 255 MW G Steam
Air
GT-1
276 MW
Exhaust gas
G
Air GT-2
Exhaust gas
ST-1
G 255 MW
Fuel
2 X 255 + 1 X 276 = 786 MW
Combined Cycle Module Configurations Fuel G
Air
GT-1
Exhaust gas
Fuel
Steam G G
Air
GT-2
Exhaust gas ST-1
Fuel G 3 X 140 + 1 X 230 = 650 MW
Air
GT-3
Exhaust gas
Combined Cycle Module Configurations Exhaust gas
Single Shaft Module
Steam
Gas Turbine
G
Steam Turbine Fuel
Air 250 MW GT + 140 MW ST = 390 MW
GAS TURBINE AUXILIARIES
STARTING MEANS- ENGINE/MOTOR/FC LUBE OIL PUMPS - MOP - AOP - EOP HYDRAULIC PUMPS- MHOP - AHOP AGB COOLING WATER PUMP
GAS TURBINE AUXILIARIES BOOSTER COMPRESSOR ATOMIZING AIR COMPRESSOR FUEL GAS CONDITIONING SKID LP FUEL OIL PUMP HP FUEL OIL PUMP COMP. WASHING SKID STARTING CLUTCH
GAS TURBINE SYSTEMS AIR INLET SYSTEM COMPRESSION SYSTEM - AIR COMPRESSOR - VIGVs - STATOR BLADES - ROTOR BLADES - EGVs
INLET PLENUM
TURBINE FILTERS
TURBINE FILTERS
VIGVs
VIGVs
COMPRESSOR ROTOR
COMP. STATOR BLADES
COMP. ROTOR X- SECTION
GAS TURBINE SYSTEMS
COMBUSTION SYSTEM - FUEL NOZZLES - CLs - TPs - X- FIRE TUBES - SPARK PLUGS - FLAME SCANNERS
FUEL NOZZLE
FUEL NOZZLE
X- FIRE TUBES
COMBUSTION LINER
TRANSITION PIECE
SPARK PLUGS
FLAME SCANNER
GAS TURBINE SYSTEMS
EXPANSION - I, II, III STAGE NOZZLES - I, II, III STAGE BUCKETS - I, II, III STAGE SHROUDS - WHEEL SPACERS
U/H TURBINE VIEW
I STAGE BUCKETS
I STAGE NOZZLE
GAS TURBINE SYSTEMS
EXHAUST -EXHAUST DIFFS - EXHAUST THERCOUPLES
HRSG & STEAM TURBINE HRSG DIVERTER DAMPER ECONOMIZER FEED CONTROL STATION EVAPORATORS SUPER HEATERS MAIN STEAM STOP VALVE
STEAM TURBINE STEAM TURBINE – STEAM CONTROL & STOP VALVE HP TURBINE LP TURBINE CONDENSER SEALING STEAM SYSTEM VACUUM PUMP
STEAM TURBINE AUXILIARIES
STEAM CONTROL SYSTEM BARREN GEAR SEALING SYSTEM LUBRICATION SYSTEM CEPs BFPs AUX. COOLING WATER SYSTEM CONDENSER & COOLING SYSTEM
CONDENSER
COOLING TOWER
COOLING TOWER
COOLING TOWER
HRSG
TYPES OF STEAM TURBINES Based
on the steam expansion- Impulse Turbine - Reaction Turbine
TYPES OF STEAM TURBINES
TYPES OF STEAM TURBINES Based
on the direction of steam flow- Radial Flow Turbine - Axial Flow Turbine
TYPES OF STEAM TURBINES
TYPES OF STEAM TURBINES Based
on the no. of stages - Single Stage Turbine - Multi Stage Turbine
TYPES OF STEAM TURBINES
TYPES OF STEAM TURBINES Based
on the Power Utilization- Industrial Turbine - Transport Turbine
TYPES OF STEAM TURBINES
TYPES OF STEAM TURBINES
Based on the Exhaust Pressure - Condensing Turbine - Back pressure Turbine - Extraction Turbine
TYPES OF STEAM TURBINES
QUESTIONS ?
K. S YADAV Manager (M-I),PPCL
Cell - 09717694741 email- [email protected]
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