Gas Turbine Combined Cycle Power Plants

545 Pages·2019·23.186 MB·\545

by  S. Can Gülen (Author)

Gas Turbine Combined
Cycle Power Plants

Gas Turbine Combined
Cycle Power Plants
S. Can Gülen
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Contents
Preface...............................................................................................................................................xi
Author ............................................................................................................................................xiii
Chapter 1 Introduction ..................................................................................................................1
1.1 Note on Units .....................................................................................................2
1.1.1 Odds and Ends ......................................................................................4
Chapter 2 Prerequisites .................................................................................................................7
2.1 Books and Periodicals .......................................................................................7
2.2 Software Tools ...................................................................................................8
2.3 Codes and Standards .......................................................................................11
References ..................................................................................................................14
Chapter 3 Bare Necessities .........................................................................................................15
3.1 Why Combined Cycle? ....................................................................................15
3.2 Combined Cycle Classification ........................................................................18
3.3 Simple Calculations .........................................................................................19
3.3.1 Design Performance ...........................................................................20
3.3.2 Off-Design Performance ....................................................................22
3.3.3 Lower or Higher Heating Value? ........................................................24
3.3.4 Gross or Net? ......................................................................................25
3.4 Operability .......................................................................................................27
References ..................................................................................................................31
Chapter 4 Gas Turbine ................................................................................................................33
4.1 Brief Overview ................................................................................................33
4.2 Rating Performance .........................................................................................38
4.3 Technology Landscape ....................................................................................39
4.4 Basic Calculations ...........................................................................................42
4.4.1 Heat and Mass Balance Analysis (First Law) ....................................42
4.4.2 Simplified Cycle Analysis ..................................................................48
4.4.3 Stage-by-Stage Gas Turbine Model ....................................................54
4.4.3.1 Turbine Aero .......................................................................55
4.4.3.2 Turbine Cooling ..................................................................64
4.4.3.3 Compressor Aero ................................................................65
4.5 Fuel Flexibility ................................................................................................71
References ..................................................................................................................73
Chapter 5 Steam Turbine ............................................................................................................75
5.1 Impulse versus Reaction ..................................................................................78
5.1.1 Steam Turbine Irreversibility .............................................................91
5.1.2 Supercritical Steam Turbine ...............................................................93
5.2 Last-Stage Bucket ............................................................................................95
v
vi Contents
5.3 Basic Calculations .........................................................................................100
5.3.1 Steam-Path Efficiency ......................................................................103
5.3.2 Steam Cycle Simple Calculation ......................................................104
5.3.3 Steam Cycle Efficiency History .......................................................108
5.3.4 Exhaust End Analysis .......................................................................110
References ................................................................................................................112
Chapter 6 Heat Recovery Steam Generator (HRSG) ................................................................115
6.1 Fundamentals of Heat Recovery ...................................................................120
6.1.1 Heat Release Diagram ......................................................................120
6.1.2 HRSG Irreversibility ........................................................................121
6.1.3 HRSG Effectiveness .........................................................................122
6.1.4 Simplest Possible HRSG: One-Pressure, No Reheat ........................123
6.1.5 Next Level: Two-Pressure HRSG .....................................................129
6.1.6 The “Ultimate” HRSG: Three-Pressure with Reheat ......................133
6.1.7 Advanced Steam Conditions ............................................................136
6.2 HRSG Performance Calculations ..................................................................136
6.2.1 HRSG Pressure Loss ........................................................................137
6.2.1.1 Stack Effect .......................................................................138
6.2.2 Heat Transfer in the HRSG ..............................................................140
6.2.3 HRSG Steam Production .................................................................144
6.2.4 Stack Temperature ............................................................................146
6.3 Supplementary (Duct) Firing .........................................................................150
6.3.1 Practical Considerations ...................................................................154
6.3.2 Aeroderivative Gas Turbine Combined Cycle ..................................155
6.4 Supercritical Bottoming Cycle ......................................................................159
6.4.1 Feasibility of Supercritical Bottoming Steam Cycle ........................163
References ................................................................................................................164
Chapter 7 Heat Sink Options ....................................................................................................165
7.1 Water-Cooled Surface Condenser .................................................................167
7.2 Wet Cooling Tower ........................................................................................172
7.3 Circulating Water Pumps and Piping ............................................................176
7.4 Air-Cooled (Dry) Condenser .........................................................................177
7.5 Heat Sink System Selection ...........................................................................181
7.6 Heat Sink Optimization .................................................................................183
7.6.1 Two-Step Condensation ....................................................................185
References ................................................................................................................188
Chapter 8 Combining the Pieces ...............................................................................................189
8.1 Topping Cycle ................................................................................................189
8.2 Bottoming Cycle ............................................................................................191
8.2.1 Theory ..............................................................................................191
8.2.2 Practice .............................................................................................194
8.3 Combined Cycle ............................................................................................197
8.3.1 Second Law Analysis .......................................................................197
8.3.2 Optimum Combined Cycle Efficiency .............................................201
8.4 History ...........................................................................................................203
Contents vii
8.5 State of the Art ..............................................................................................215
8.6 The Hall of Fame ...........................................................................................221
8.6.1 Irsching .............................................................................................221
8.6.2 Bouchain ...........................................................................................222
8.6.3 Inland Empire Energy Center ..........................................................223
8.6.3.1 Steam-Cooled H Technology ............................................223
8.6.3.2 IEEC 107H........................................................................224
8.6.3.3 Fuel Gas Moisturization ...................................................225
8.6.4 60% Net (LHV) Bogey ....................................................................226
8.6.5 Epilogue............................................................................................228
References ................................................................................................................228
Chapter 9 Major Equipment ......................................................................................................231
9.1 Gas Turbine Package .....................................................................................231
9.2 Steam Turbine Package .................................................................................234
9.2.1 Steam Valves ....................................................................................236
9.2.2 Steam Seal Regulator (SSR) .............................................................238
9.2.3 Gland Seal Condenser (GSC) ...........................................................240
9.2.4 Turning Gear ....................................................................................240
9.2.5 Protective Features ...........................................................................240
9.3 Heat Recovery Steam Generator (HRSG) .....................................................241
9.4 AC Generator .................................................................................................247
9.5 Scope of Supply .............................................................................................251
References ................................................................................................................253
Chapter 10 Balance of Plant .......................................................................................................255
10.1 Electrical Equipment .....................................................................................255
10.1.1 Plant Controls ...................................................................................258
10.1.2 Plant Instrumentation .......................................................................260
10.2 Pipes and Valves ............................................................................................260
10.2.1 Steam System ...................................................................................263
10.2.2 Valves ...............................................................................................265
10.3 Pumps ............................................................................................................268
10.3.1 Pumps Shown in Plant Heat and Mass Balance ...............................268
10.3.2 Pumps Not Shown in Plant Heat and Mass Balance ........................269
10.3.3 Pump Selection and Design..............................................................269
10.4 Tanks .............................................................................................................273
10.5 Auxiliary Boiler ............................................................................................274
10.6 Fuel Gas Booster Compressor .......................................................................275
10.7 Fuel Gas Heating and Conditioning System .................................................276
10.8 Closed Cooling Water (CCW) System ..........................................................278
10.9 Water Facilities ..............................................................................................279
10.9.1 Why Treatment? ...............................................................................279
10.9.2 Once-Through (Benson) HRSG .......................................................283
10.9.3 Usage Minimization .........................................................................284
10.9.4 Wastewater Treatment ......................................................................285
10.9.5 Zero Liquid Discharge .....................................................................286
10.9.6 Water Balance ..................................................................................288
10.9.7 Deaeration ........................................................................................288
References ................................................................................................................292
viii Contents
Chapter 11 Construction and Commissioning ............................................................................293
11.1 Procurement ...................................................................................................297
11.2 Construction ..................................................................................................298
11.3 Startup and Commissioning ..........................................................................301
11.3.1 HRSG Steam Blow ...........................................................................302
11.4 Acceptance Tests ...........................................................................................305
11.5 General Arrangement ....................................................................................309
Chapter 12 Environmental Considerations .................................................................................313
12.1 Air Permits ....................................................................................................315
12.2 Continuous Emissions Monitoring System (CEMS) ....................................321
12.3 Noise Abatement ...........................................................................................322
12.4 Selective Catalytic Reduction ........................................................................324
12.4.1 NOx Emission Calculations .............................................................325
References ................................................................................................................326
Chapter 13 Economics ................................................................................................................327
13.1 Price versus Cost ...........................................................................................327
13.2 Cost Estimation .............................................................................................330
13.2.1 Simplified .........................................................................................331
13.2.2 Detailed ............................................................................................338
13.3 Cost of Electricity ..........................................................................................342
13.4 Value of 1 Btu/kWh of Heat Rate..................................................................346
13.5 Bottoming Cycle “Optimization” ..................................................................348
13.5.1 LCOE Dissected ...............................................................................349
13.5.2 Two-Pressure or Three-Pressure? ....................................................353
References ................................................................................................................359
Chapter 14 Cogeneration.............................................................................................................361
Chapter 15 Operability ...............................................................................................................371
15.1 Steady-State Operation ..................................................................................374
15.1.1 Hot Day Power Augmentation ..........................................................384
15.1.2 Drum-Type versus Once-Through (Benson) Control .......................387
15.2 Transient Operation .......................................................................................391
15.3 GTCC Startup: Basics ...................................................................................393
15.3.1 Steam Turbine Roll ...........................................................................396
15.3.2 Steam Turbine Stress Control ...........................................................398
15.3.3 HRSG Stress Control .......................................................................399
15.4 GTCC Startup: Practical Considerations.......................................................401
15.4.1 Steam Bypass Systems .....................................................................403
15.4.2 HP Turbine Exhaust Temperature Control .......................................405
15.4.3 Fast versus “Slow” ............................................................................405
15.5 GTCC Shutdown ...........................................................................................408
15.6 Emergencies ...................................................................................................410
15.7 Grid Code Compliance ..................................................................................412
References ................................................................................................................417
Contents ix
Chapter 16 Maintenance .............................................................................................................419
16.1 Maintenance Costs ........................................................................................421
16.2 Important Metrics ..........................................................................................424
16.2.1 Availability Calculation Example ....................................................428
16.3 Failure Mechanisms ......................................................................................431
References ................................................................................................................437
Chapter 17 Repowering ..............................................................................................................439
17.1 Which Repowering? ......................................................................................441
17.2 Cost of Repowering .......................................................................................442
17.3 An Example Calculation ...............................................................................444
17.4 Takeaways ......................................................................................................450
References ................................................................................................................451
Chapter 18 Integrated Gasification Combined Cycle .................................................................453
18.1 Syngas-Fired Gas Turbine .............................................................................457
18.2 Bottoming Cycle ............................................................................................460
18.3 Gasification ....................................................................................................462
18.3.1 Gasifier Types ...................................................................................462
18.3.2 Cold Gas Efficiency ..........................................................................462
18.3.3 Gasifier Heat Recovery ....................................................................464
18.3.4 Air Separation Unit ..........................................................................464
18.3.5 Syngas Cleanup ................................................................................466
18.3.6 Syngas Expander ..............................................................................467
18.3.7 Syngas Heating and Moisturization .................................................467
18.3.8 Carbon Capture and Sequestration...................................................468
18.4 Example .........................................................................................................470
References ................................................................................................................474
Chapter 19 Carbon Capture ........................................................................................................475
19.1 Post-Combustion Carbon Capture Basics......................................................476
19.1.1 State of the Art .................................................................................476
19.1.2 A Novel Method ...............................................................................478
19.1.3 A Novel Operating Strategy .............................................................480
19.2 Simple Calculations .......................................................................................483
References ................................................................................................................485
Chapter 20 What Next? ...............................................................................................................487
Appendix A: Property Calculations ...........................................................................................491
Appendix B: Standard Conditions for Temperature and Pressure ........................................497
Appendix C: Exergetic Efficiency ...............................................................................................499
Appendix D: Thermal Response Basics .....................................................................................503
Appendix E: Steam Turbine Stress Basics ................................................................................507