Fixed Duct Burner Heat Input Approach for Combined Cycle Power Plant ASME PTC 46 Performance Testing

2011 ◽  
Author(s):  
Thomas K. Kirkpatrick ◽  
Bernard J. Pastorik ◽  
Wesley M. Newland
Keyword(s):  
Heat Input ◽  
Heat Rate ◽  
Combined Cycle ◽  
Test Method ◽  
Plant Performance ◽  
Ambient Conditions ◽  
Power Test ◽  
Alternative Approach ◽  
Combined Cycle Plant ◽  
Duct Burner

Since its publication in 1996, ASME PTC 46 Performance Test Code on Overall Plant Performance has established itself as the premier test code for conducting overall plant performance within the power industry, especially for combined cycle power plants. The current text within ASME PTC 46, which is currently under revision by the ASME PTC 46 Committee, describes in Section 5.3.4 Specified Measured Net Power that “This test is conducted for a combined cycle power plant with duct firing or other form of power augmentation, such as steam or water injection when used for that purpose.” Further, the only example problem for a combined cycle with duct firing is provided in Appendix B of the code utilizing the Specified Measured Net Power Test Method. Though the text and example are correctly presented within the code, it resulted in misinterpretation within the industry that the only correct way to test a combined cycle plant with duct firing was to conduct a Specified Measured Net Power Test. Though the Specified Measured Net Power Test Method is an acceptable and accurate method in determining the performance of a combined cycle plant with duct firing in operation, it lends to being inflexible to the weather conditions for the plant operation. When the weather is too cold, the exhaust energy from the combustion turbines may be at such a magnitude as to not allow the duct burners to be fired due to limitations within the heat recovery steam generator and steam turbine systems to take the load, thus limiting the plant testing to take place when the weather is warm enough to allow the plant to be operated with duct firing. The opposite condition can also exist where the ambient conditions are too hot so that the duct burner capacity is unable to achieve the specified measured net power allowing the test to be conducted. The limitations stated herein are the reasons that an alternative approach with more flexibility is necessary. This paper will present an alternative approach referred to as the Fixed Duct Burner Heat Input Test Method to testing combined cycle plants where the duct burner heat input (Fuel Flow) is held fixed while the plant net power and heat rate are left to float with ambient conditions. Corrections for both power and heat rate will be developed for ambient conditions per ASME PTC 46 guidelines. This paper will further present a comparison between the Specified Measured Net Power Test Method and the Fixed Duct Burner Heat Input Test Method in the areas of the flexibility of the methods for various ambient conditions, and the method uncertainty associated with each method’s ability to correct to reference conditions.

Hot Windbox and Combined Cycle Repowering to Improve Heat Rate

2010 ◽  
Author(s):  
Tarek A. Tawfik ◽  
Thomas P. Smith
Keyword(s):  
Steam Turbine ◽  
Gas Turbine ◽  
Gas Turbines ◽  
Heat Recovery ◽  
Heat Rate ◽  
The United States ◽  
Combined Cycle ◽  
Plant Performance ◽  
Ambient Conditions ◽  
North East

Retrofitting existing power generation plants by repowering is becoming an attractive option to improve plant performance with less cost. “Hot Windbox Repowering” involves utilizing the hot exhaust gas from a combustion gas turbine and using it as combustion air for an existing fossil-fuel boiler. “Combined Cycle Repowering” or “Full Repowering” involves completely replacing the existing boiler with a combined cycle consisting of a gas turbine(s) and a heat recovery steam generator (HRSG). The existing steam turbine will be used in both repowering scenarios. This paper discusses an engineering study and summarizes the results obtained from repowering an existing heavy-oil / natural gas fired steam power plant in the north east of the United States. The plant consists of a 600 MW boiler and steam turbine. Several engineering studies were considered and evaluated thermodynamically and economically to retrofit such plant. Several options were considered involving different gas turbines, gas turbine combinations, and different repowering methods. The best option is based on retrofitting the unit by a combination of both, hot windbox repowering and combined cycle repowering. The proposed design consists of one gas turbine repowering the windbox of the existing boiler, and a second gas turbine operating in a separate combined cycle configuration with the generated superheated steam tying into the main steam line and expanding in the existing steam turbine. Several heat balances were developed to assist in obtaining meaningful results for this feasibility study. Actual costs were obtained for the gas turbines and heat recovery steam generators (HRSG), as well as installation costs for a more accurate evaluation. The results indicate that the combined output of the repowered unit will generate an additional 295 MW and reduce the heat rate by more than 11 percent at full load and annual average ambient conditions. The estimated capital cost of the project is expected to range from $235 to $245 millions.

Gas Turbine Plant Thermal Performance Degradation Assessment

2008 ◽  
Author(s):  
Alexander V. Mirzamoghadam
Keyword(s):  
Gas Turbine ◽  
Performance Monitoring ◽  
Heat Rate ◽  
Performance Degradation ◽  
Combined Cycle ◽  
Plant Performance ◽  
Power Plant Equipment ◽  
Combined Cycle Plant ◽  
Plant Level ◽  
Compressor Power

Knowing the sources behind degradation of gas turbine power and heat rate and the performance of other power plant equipment are critical to equipment manufacturers for guaranteeing their respective performances over the life cycle as well as to utility/plant owners for cost reasons. Many power companies are trying to improve equipment reliability by focusing on Performance Monitoring and the application of advanced diagnostic technologies. The first part of the paper describes a method to monitor gas turbine compressor efficiency, forecast an efficiency decay rate in terms of operating hours, introduce the logic leading to an optimum schedule pertaining on-line/off-line water washing, correct measured real-time gas turbine power and heat rate with respect to the new and clean reference point, and then deduce the respective turbine and compressor power contributions to gas turbine net power degradation. An example is used to aid the planning of a rigorous but effective schedule in compressor washing. The second part focuses on assessing degradation at the plant level (simple or combined cycle). The derived gas turbine degradation methodology is integrated with the overall plant performance degradation, and as a result, the maintenance effectiveness of the most recent outage can be measured. The proposed methodology is applied to a hypothetical combined cycle plant, allowing the identification of possible sources of plant deterioration with recommendations for corrective actions to improve overall power and heat rate.

scholarly journals Compressor Washing Maintains Plant Performance and Reduces Cost of Energy Production

1994 ◽  
Author(s):  
Jean-Pierre Stalder ◽  
Peter van Oosten
Keyword(s):  
Energy Production ◽  
Combined Cycle ◽  
Plant Performance ◽  
Atmospheric Conditions ◽  
Output Level ◽  
Maintenance Program ◽  
Cost Of Energy ◽  
Combined Cycle Plant ◽  
On Line ◽  
High Output

This paper reports about the results of a field test conducted over a period of 8000 operating hours on the effect of combined on line and off line compressor washing on a 66 MW gas turbine operating in a combined cycle plant at UNA’s Lage Weide 5 power plant in Utrecht. Observations have shown a sustained high output level close to the nominal guaranteed rating, despite difficult atmospheric conditions. Investigations on the correlations between fouling gradients in the compressor and atmospheric conditions are also presented. The evaluation of the results demonstrate the importance of implementing an optimised regime of on line and off line washing in the preventive turbine maintenance program. It will improve the plant profitability by reducing the costs of energy production.

Degradation Effects on Combined Cycle Power Plant Performance: Part 1 — Gas Turbine Cycle Component Degradation Effects

2001 ◽  
Author(s):  
A. Zwebek ◽  
P. Pilidis
Keyword(s):  
Gas Turbine ◽  
Combined Cycle ◽  
Plant Performance ◽  
Plant Design ◽  
Turbine Performance ◽  
Fortran Code ◽  
Steam Turbine Plant ◽  
Combined Cycle Plant ◽  
Gas Turbine Exhaust ◽  
Topping Cycle

This paper describes the effects of degradation of the main gas path components of the gas turbine topping cycle on the Combined Cycle Gas Turbine (CCGT) plant performance. Firstly the component degradation effects on the gas turbine performance as an independent unit are examined. It is then shown how this degradation is reflected on a steam turbine plant of the CCGT and on the complete Combined Cycle plant. TURBOMATCH, the gas turbine performance code of Cranfield University was used to predict the effects of degraded gas path components of the gas turbine have on its performance as a whole plant. To simulate the steam (Bottoming) cycle, another Fortran code was developed. Both codes were used together to form a complete software system that can predict the CCGT plant design point, off-design, and deteriorated (due to component degradation) performances. The results show that the overall output is very sensitive to many types of degradation, specially in the turbine of the gas turbine. Also shown is the effect on gas turbine exhaust conditions and how this affects the steam cycle.

Combined Heat and Power Plants Based on Mirror Heat Exchange Brayton Cycles

2014 ◽  
Author(s):  
Andrea Passarella ◽  
Gianmario L. Arnulfi
Keyword(s):  
Heat Recovery ◽  
Power Plants ◽  
Combined Heat And Power ◽  
Combined Cycle ◽  
Plant Performance ◽  
Higher Power ◽  
Combined Cycle Plant ◽  
Gas Turbine Exhaust ◽  
Interesting Alternative ◽  
Top Cycle

As gas turbine exhaust gases leave the turbine at high temperature, heat recovery is often carried out in a combined heat-and-power system or in the steam section of a combined-cycle plant. An interesting alternative is a mirror cycle, which involves coupling together a direct Brayton top cycle and an inverted Brayton bottom cycle; this results in significantly higher power output and efficiency, though at the expense of added complexity. The research illustrated in the present paper was based on two in-house codes and aimed to analyze different plant configurations, one of which was a heat recovery (regenerative) top cycle with the heat exchanger hot side located between the top and bottom cycle turbo-expanders. The authors call this configuration a distorting mirror, as the hot side may not be at atmospheric pressure. A parametric analysis was carried out in order to optimize plant performance vs. pressure levels. Simulation showed that, at the design point, very good performance is obtained: efficiency close to 0.50 with plant cost (per megawatt) about half vs. combined-cycle plants. An off-design analysis showed that the mirror plant is a little more sensitive to changes in load than a simple Brayton, single-shaft GT.

Improved Performance and Reduced Emission From Coal and Gas Fuelled GT-SOFC and GT-MCFC Plants: Some Studies

2006 ◽  
Author(s):  
S. Ghosh ◽  
S. De ◽  
S. Saha
Keyword(s):  
Natural Gas ◽  
Emission Reduction ◽  
Coal Gasification ◽  
Energy Savings ◽  
Combined Cycle ◽  
Plant Performance ◽  
Co2 Emission Reduction ◽  
Simulated Performance ◽  
Combined Cycle Plant ◽  
Improved Performance

This paper presents conceptual models of some novel GT-SOFC and GT-MCFC plants for power and cogeneration operating on gasified coal or natural gas. Simulated performance of the modeled plants in terms of energy efficiency, emission reduction, fuel energy savings (for cogeneration) with respect to separate reference plants for power generation and utility heat production is presented and analyzed. Influences of variations in some design and operating parameters on the plant performance are also reported in the paper. A study with a coal gasification combined cycle plant using SOFC upstream of GT suggests that such plants have the potential of delivering power at an overall efficiency level exceeding 50%. A similar plant delivering both power and utility heat can potentially save about 30% of fuel with respect to separate plants for power and heat. For a conceptualized natural gas fuelled GT-MCFC CHP plant, an electrical efficiency of more than 40% and fuel energy saving exceeding, 30% are achievable. Using a CO2 separator placed at fuel cell exhaust, CO2 can be trapped in a closed cycle. CO2 emission reduction as high as 60% is achievable for such plants.

LM2500+ Single Shaft Combined Cycle With Frequency Stabilization

1998 ◽  
Author(s):  
Donald A. Kolp ◽  
Charles E. Levey
Keyword(s):  
Steam Turbine ◽  
Gas Turbine ◽  
Heat Recovery ◽  
Heat Rate ◽  
Combined Cycle ◽  
Heat Recovery Steam Generator ◽  
Equipment Operation ◽  
Combined Cycle Plant ◽  
Stable Frequency ◽  
And Performance

Zorlu Enerji needed 35 MW of reliable power at a stable frequency to maintain constant speed on the spindles producing thread at its parent company’s textile plant in Bursa, Turkey. In December of 1996, Zorlu selected an LM2500+ combined cycle plant to fill its power-generating requirements. The LM2500+ has output of 26,810 KW at a heat rate of 9,735 Kj/Kwh. The combined cycle plant has an output of 35,165 KW and a heat rate of 7,428 Kj/Kwh. The plant operates in the simple cycle mode utilizing the LM2500+ and a bypass stack and in combined cycle mode using the 2-pressure heat recovery steam generator and single admission, 9.5 MW condensing steam turbine. The generator is driven through a clutch by the steam turbine from the exciter end and by the gas turbine from the opposing end. The primary fuel for the plant is natural gas; the backup fuel is naphtha. Utilizing a load bank, the plant is capable of accepting a 12 MW load loss when the utility breaker trips open; it can sustain this loss while maintaining frequency within 1% on the mill load. The frequency stabilizing capability prevents overspeeding of the spindles, breakage of thousands of strands of thread and a costly shutdown of the mill. A description of the equipment, operation and performance illustrates the unique features of this versatile, compact and efficient generating unit.

Effect of Fuel Gas Cleanup Option on Air-Blown IGCC Power Plant Performance

1997 ◽  
Author(s):  
W. C. Yang ◽  
R. A. Newby ◽  
R. L. Bannister
Keyword(s):  
Power Plant ◽  
Process Model ◽  
Coal Gasification ◽  
Heat Rate ◽  
Combined Cycle ◽  
Plant Performance ◽  
Fuel Gas ◽  
Gas Cleaning ◽  
Plant Sensitivity ◽  
Parametric Studies

Air-blown coal gasification for combined-cycle power generation is a technology soon to be demonstrated. A process evaluation of air-blown IGCC performed to estimate the plant heat rate, electrical output and potential emissions are described in this paper. A process model of an air-blown IGCC power system based on the Westinghouse 501F combustion turbine was developed to conduct the performance evaluation. Parametric studies were performed to develop an understanding of the power plant sensitivity to the major operating parameters and process options. Advanced hot fuel gas cleaning and conventional cold fuel gas cleaning options were both considered.

Upgrades of Steam Turbine Generator Units in Watson Cogeneration Combined Cycle Plant

2002 ◽  
Author(s):  
Steve Ingistov
Keyword(s):  
High Pressure ◽  
Steam Turbine ◽  
Heat Rate ◽  
Combined Cycle ◽  
High Pressure Steam ◽  
Turbine Generators ◽  
Pressure Steam ◽  
Combined Cycle Plant ◽  
Path Modification ◽  
Sealing Elements

This paper describes efforts that were implemented in modifying two Steam Turbine Generators (STG) that are presently operating in Watson Cogeneration Company (WCC) Plant. WCC Plant is comprised of four identical GE made Gas Turbine Generators (GTG) and four Heat Recovery Steam Generators (HRSG) designed and fabricated by Vogt. Portion of high pressure steam is expanded inside two Dresser-Rand-made Steam Turbine Generators (STG). The modifications presented in this paper include replacement of six original stages of expansion, introduction of shaft retractable labyrinths/packing and installation of the spill strips around shrouded blades. The modifications of high pressure steam path (except 1st stage blading) were completed in 1992 and modification of rotor steam sealing elements such as shaft labyrinths were completed in April and May 2001. The steam path modification uprated STG from original 34.50MW to present 40MW each. The upgrades of the rotor sealing elements resulted in 2.80% Heat Rate (HR) reduction.

Combined Cycle Plant Performance Monitoring

2004 ◽  
Author(s):  
Michael McClintock ◽  
Kenneth L. Cramblitt
Keyword(s):  
Thermal Performance ◽  
Gas Turbines ◽  
Power Plants ◽  
Performance Monitoring ◽  
Monitoring Program ◽  
Combined Cycle ◽  
Plant Performance ◽  
Testing Procedures ◽  
Combined Cycle Plant ◽  
Reheat Steam

Monitoring thermal performance in the current generation of combined cycle power plants is frequently a challenge. The “lean” plant staff and organizational structure of the companies that own and operate these plants frequently does not allow the engineering resources to develop and maintain an effective program to monitor thermal performance. Additionally, in many combined cycle plants the highest priority is responding to market demands rather than maintaining peak efficiency. Finally, in many cases the plants are not designed with performance monitoring in mind, thus making it difficult to accurately measure commonly used indices of performance. This paper describes the performance monitoring program being established at a new combined cycle plant that is typical of many combined cycle plants built in the last five years. The plant is equipped with GE 7FA gas turbines and a GE reheat steam turbine. The program was implemented using a set of easy-to-use spreadsheets for the major plant components. The data for the calculation of indices of performance for the various components comes from the plant DCS system and the PI system (supplied by OSIsoft). In addition to the development of spreadsheets, testing procedures were developed to ensure consistent test results and plant personnel were trained to understand, use and maintain the spreadsheets and the information they produce.

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