Combined Cycle Development Evolution and Future GER4206
Combined Cycle Development Evolution and Future GER4206
Combined Cycle Development Evolution and Future GER4206
GER-4206
GE Power Systems
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Figure 1. STAG 209E combined-cycle part load performance less than 60 minutes. Combined-cycle plants also provide efficient operation at part load, particularly for multiple gas turbine combined-cycle systems. This is illustrated by the variation in plant output with variation in plant heat rate curve shown for a General Electric STAG 200 system (See Figure 1). Modulating compressor inlet guide vanes are standard features of many gas turbine GE Power Systems GER-4206 (10/00)
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and packaging of major components in the factory. Phased installation of the plant, when gas turbines are installed and op-erated in the simple-cycle mode during the steam-cycle equipment installation, enables the user to generate power and revenue in as little as a year from order date (See Figures 24). A typical combined-cycle plant installation schedule is presented in Figure 5. 2
Figure 3. Two STAG 407B combined-cycle steam system installation GE Power Systems GER-4206 (10/00)
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Figure 5. Typical project schedule costs are achieved through quality design, prudent operation, and equipment design that allow convenient access for component inspection. 8. High Efficiency in Small Capacity Increments - Gas turbine generators are designed and manufactured in discrete frame sizes. For example, the General Electric heavy-duty, gas turbine-packaged power plant product line includes the MS6001B (50 Hz and 60 Hz), MS7001 FA (60 Hz), MS7001B (60 Hz) and the MS9001 FA (50 Hz) units, which cover an output range of approximately 37 MW to 250 MW. Application of these gas turbine models in combined-cycle
Figure 6. Gas turbine in first power generation combined cycle GE Power Systems GER-4206 (10/00)
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BOILERS
STEAM TB
GEN
COND
LP HEATER
Figure 7. OG&E Belle Isle feedwater heating repowering system cycle diagram
the first generation systems. Table 2 and Table 3 represent second generation characteristics and experience. The requirements for stack gas NOx emission control was initially legislated during the late 1970s. The first systems utilized gas turbine water or steam injection to meet new source performance standards of 75 ppmvd at 15% oxygen with efficiency and fuel-bound nitrogen adjustments. Combined-cycle plants utilized steam from the steam cycle for NOx control because this had the least impact on plant efficiency. As emission requirements became more stringent, it was necessary to apply SCR to augment NOx abatement (TEPCO Groups I and II). Application of SCR systems became common in Japan and in the USA in the mid-1980s.
50-90 MW Capacity (MS6000B, MS7000B/C/E and MS9000B/E Heat Recovery Feedwater Heating CC from 1968-1999 Non-reheat, Single, Two & Three Pressure GT Water and Steam Injection plus Selective Catalytic Reduction System (SCR) Installed in the HRSG Gas Path for NOx Control Natural Gas / Distillate Oil / Low Btu Gas / Oils
Fuel Heavy
Table 2. Second generation combined-cycle system characteristics in Figure 8 performance maps as a function of firing temperature and pressure ratio parameters. Specific power (i.e., output per pound of airflow) is important since the higher the value, the smaller the gas turbine required for design power output. The importance of thermal efficiency is obvious since it directly impacts the operating fuel cost. Figure 8 illustrates a number of significant points. 1. Where simple-cycle efficiency is the goal, high pressure ratio is desirable. 2. Where combined-cycle efficiency is the objective, more modest pressure ratios are selected. 3. Firing temperature has a greater impact on combined-cycle efficiency than simple-cycle efficiency. Fuel price escalation in the 1970s and 1980s further increased the need for more efficient power plants for base- and mid-range service. This led to gas turbine designs in the late 1980s that were optimized specifically for combinedcycle efficiency.
Country Argentina Japan China Pakistan Japan Egypt Austria Indonesia Egypt Indonesia Turkey Malaysia China Pakistan Ghana
Second Generation 50 Hz. STAG Combined Cycle Experience Installation Configuration COD Total (MW) EMSA S205P 1984 65 TEPCO, Futtsu #1 7 x S109E * 1986 1155 MPI Lama Dien II S106B * 1986 50 WAPDA 2 x S209E 1986 623 TEPCO, Futtsu #2 7 x S109E * 1988 1155 Egyptian Electric Authority 2 x S 405P 1988 300 ESG Linz S206B 1993 77 PLN-Maura Karang S309E 1995 500 EEA Cairo South S109E 1994 180 PLN-Tambrok Lorok 2 x S309E 1996 1000 Colakoglu S209E 1996 370 TNB/Melaka S209E 1998 340 Wenzhou S209E 1999 313 Uch S309E 2000 560 Vra/Takaradi S209E 2000 337
= 52 units = 7,052 MW
Table 3. Second generation combined-cycle experience The GE F Technology gas turbine designed in the 1980s, with pressure ratio of about 14:1 and 2400F firing temperature was the result of a design effort aimed at optimization for combined-cycle peak efficiency rather than simplecycle peak efficiency. The fleet leader F Technology gas turbine entered commercial operation in 1990 in a combined-cycle installation at the Virginia Power Chesterfield site and launched the third generation of combined-cycle systems.
Figure 8. Gas turbine performance thermodynamics The third generation F Technology combined-cycle experience is summarized in Table 4 and system characteristics are defined in Table 5. The trend of combined-cycle plant efficiency improvement is illustrated by Figure 9, which shows the performance of selected STAG plant installations as a function of commercial operating date. Gas turbine development has had the greatest impact on improved combinedcycle efficiency due primarily to the increase in firing temperature made possible through the development of high-temperature oxidation/ corrosion-resistant metals and coatings, and advanced metal surface cooling techniques. Another important factor is that the gas turbine contributes about two-thirds of the combinedcycle plants power. Advances in steam system technology have also contributed to improved combined-cycle efficiency. The significant steam-cycle developments include: 1. Technology to weld continuous spiral fins on HRSG heat transfer tubes (1959). 2. Application of larger annulus area steam turbine designs for low exhaust pressure applications. GE Power Systems GER-4206 (10/00)
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3. Application of reheat steam cycle with F Technology gas turbines. The current STAG product line ratings, which represent third generation combined-cycle capability, is summarized in Figure 10.
= 2 Units = 12,411 MW
50 Hz. STAG Combined Cycle Experience with F Technology Gas Turbine Country Installation Configuration COD Output (MW) Japan TEPCO, Yokahama 8 x S109FA * 1996/7 2800 China China Power & Light 8 x S109FA * 1996/72 2731 Japan TEPCO, Chiba 4 x S109FA * 1998 1440 India Enron, Dabhol I S209FA 1998 698 Chile Renca S109FA 1998 370 Netherlands AKZO, Delesto S109FA * 1999 364 U.K. Sutton Bridge S209FA 1999 800 Thailand Ratchaburi 3 x S209FA 2000 2130 Argentina Central Puerto S209FA 2000 769 Japan Hitachi Zosen S106FA 1999 106 U.K. Tri-Energy S209FA 2000 700 U.K. Great Yarmouth S109FA * 2001 407 India Enron, Dabhol II 2 x S209FA 2001 1600 Japan TEPCO, Futtsu 3 4 x S109FA * 2002 1590 Spain Castellon S209FA 2002 285 * Single-shaft Combined Cycle
= =
50 units 17,795 MW
70-250 MW (MS6001FA, MS7001FA, MS9001EC and MS9001FA) Heat Recovery Feedwater Heating CC in the 1990s Reheat, Three Pressure DLN Combustion with Natural Gas and Water / Steam Injection with Oil Fuels plus SCR Installed in the HRSG Natural Gas / Distillate Oil / Low Btu Gas
Fuel
Table 5. Third generation combined-cycle system characteristics GE Power Systems GER-4206 (10/00)
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60 55 50 45
40
(11)
(3)
1980
1990
2000
Notes: 1. Site Conditions: 59F, 14.7 Psia , 60% Rh 2. Fuel is Natural Gas 3. Steam Turbine Exhaust Pressure: 1.2 inches Hg,a
60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 0
Third Generation F F Technology Gas Turbines Reheat, Three Pressure Steam Cycle
S109EC (50Hz) S109E (50Hz) Second Generation B And E Technology Gas Turbines Non-Reheat, Three-Pressure SteamCycle
Net plant Output (MW) 50 100 150 200 250 300 350 400 450 500
Figure 10. Current STAG product line ratings generation plants with H Technology gas turbines will be configured with an integrated closed-loop steam cooling system (See Figure 11). This system allows higher turbine firing temperature to be achieved without increasing combustion temperature. This is because exhaust gas temperature drop across the first stage nozzle is significantly reduced as outlined in Figure 12. Another important benefit of the integrated closed-loop steam cooling system is the elimination of chargeable cooling air for the first and second stage rotating and stationary airfoils. This GE Power Systems GER-4206 (10/00)
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technology is expected to provide two percentage points thermal efficiency improvement. The H platform gas turbine combined-cycle plants are expected to achieve 60% LHV thermal efficiency in the first half of this decade. The application of ceramic hot gas path parts and coatings show promise for further future performance gains. Steam cycle improvements that include increased steam pressure and temperature with supercritical steam cycles have near-term applica11
Fu el He a tin g S ys te m
H e at Re c ov e ry S te a m G e ne r ato r
To S ta ck
C oo lin g A ir C oo ling S y st e m
A ttem p
F il te r
HP
IP
LP
LP
G en er a tor
F e ed w a ter Pu m p
G a s Tu rb in e
L E G E ND S te a m W a te r E x ha u s t Air Fu e l
A ir T re atm en t
S te a m Tu rb in e C oo lin g W a te r
Deaerating Condenser
Filter A
Ai r Co nd en sa te P u m p
Filter B C on de ns a te Fil te r
G la n d S ea l Co nd e n se r
Figure 11. S107H/S109H cycle diagram tion. Current economic analysis indicates, however, that the thermodynamic gain associated with steam cycles that have steam temperatures and pressures above the current levels (1050F and 1400 PSIG to 1800 PSIG) cannot be justified in most cases because of the added costs. As in the past, operating cost (fuel price) and the cost of new technology development will dictate the trend for increased combined-cycle efficiency.
Figure 12. Impact of stage one nozzle cooling method GE Power Systems GER-4206 (10/00)
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List of Figures
Figure 1. STAG 209E combined-cycle part load performance Figure 2. Six MS7001B gas turbines Figure 3. Two STAG 407B combined-cycle steam system installation Figure 4. Two STAG 407B combined cycle Figure 5. Typical project schedule Figure 6. Gas turbine in first power generation combined cycle Figure 7. OG&E Belle Isle feedwater heating repowering system cycle diagram Figure 8. Gas turbine performance thermodynamics Figure 9. Combined-cycle system efficiency trend Figure 10. Current STAG product line ratings Figure 11. S107H / S109H cycle diagram Figure 12. Impact of stage one nozzle cooling method
List of Tables
Table 1. Gas turbine in first power generation combined cycle Table 2. Second generation combined-cycle system characteristics Table 3. Second generation STAG power generation experience Table 4. Third generation combined-cycle experience Table 5. Third generation combined-cycle system characteristics
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