OVERVIEW OF COMBINED CYCLE

TURBINE TECHNOLOGY
9/30/2014

MATTHEW ESPER, MECHANICAL ENGINEER

ENERGY
BSME ’06 – UofM
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AGENDA
• Who Is Black & Veatch?
• Overview of Traditional Thermal Cycles
• Overview of Combined Cycles
• Major Equipment of Combined Cycles
• Design Options for Combined Cycles
AGENDA

• Air Quality Control for Combined Cycles

• Review of Latest CTG in CC Technology
Options
• New Hire Responsibilities
• Questions

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WHO IS
BLACK & VEATCH?

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 9/30/2014

WE’RE BUILDING A WORLD OF

DIFFERENCE. TOGETHER.
• Founded in 1915
• Global workforce of more than 10,000
W H O I S B L A C K & V E AT C H ?

• Employee-owned corporation
• $3.6 billion in annual revenues in 2013
• More than 110 offices worldwide
• Completed projects in more than
100 countries

Black & Veatch conducts 7,000+ active projects

globally at any one time 4
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SOLVING THE WORLD’S COMPLEX

CHALLENGES IN EACH OF OUR MARKETS
Energy Water Telecommunications
Indonesia Hong Kong SAR California, USA
W H O I S B L A C K & V E AT C H ?

Security Management Consulting Environmental

Armenia Oklahoma, USA Scotland, UK

Using teamwork and collaboration we provide

sustainable and reliable solutions 5
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BLACK & VEATCH PROVIDES CONSTRUCTION

SERVICES TO THE ENERGY, WATER,
TELECOMMUNICATIONS AND FEDERAL MARKETS
W H O I S B L A C K & V E AT C H ?

Black & Veatch Overland Contracting Inc. Black & Veatch

Construction, Inc. (BVCI) (OCI) for open shop International (BVI) for
for union construction construction work outside the U.S.

We have extensive construction experience on

projects of complex size and scope throughout the
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world
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THE RESULT IS A POSITION OF

INDUSTRY LEADERSHIP

ENR
1st – Top 20 in Telecommunications
1st – Top 25 in Fossil Fuel
3rd – Top 20 in Power
3rd – Top 20 in Transmission Lines and Aqueducts
W H O I S B L A C K & V E AT C H ?

Engineering News-Record
4th – Top 25 in Transmission and Distribution Plants
4th – Top 20 Contractors in Telecom
5th – Top 10 in Hydroplants
5th – Top 20 in Nuclear Plants
5th – Top 15 in Dams and Reservoirs
6th – Top 25 in Wastewater Treatment Plants
6th – Top 25 in Sanitary and Storm Sewers
6th – Top 20 in Water
8th – Top 20 in Sewerage and Solid Waste
9th – Top 20 Contractors in Power
10th – Top 20 in Water Treatment, Desalination Plants
11th – Top 50 Contractors Working Abroad
12th – Top 25 in Refineries and Petrochemical Plants
16th – Top 500 Design Firms

CENTURION2 nd
– Top 100 Federal Contractors
Architectural & Engineering Services
RESEARCH SOLUTIONS
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BLACK & VEATCH HAS REGIONAL OFFICES

THROUGHOUT THE UNITED STATES
Arizona
California
Colorado
Delaware
W H O I S B L A C K & V E AT C H ?

District of Columbia
Florida
Georgia
Illinois
Indiana
Kansas
Kentucky
Louisiana
Maryland
Massachusetts
Michigan
Minnesota
Missouri
Nebraska
Nevada
New Jersey
New York
North Carolina
Ohio
Oregon
Pennsylvania
South Carolina Project offices are not included.
Texas
Virginia
Washington 8
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OUR GLOBAL PRESENCE ALLOWS US TO

APPLY GLOBAL EXPERTISE LOCALLY
W H O I S B L A C K & V E AT C H ?

Afghanistan Georgia Oman Taiwan

Armenia Hong Kong Palestine Thailand
Australia India Philippines Turkey
Azerbaijan Indonesia Puerto Rico Ukraine
Bahrain Kuwait Russia United Arab Emirates (UAE)
Canada Kazakhstan Saudi Arabia United Kingdom
Chile Malaysia Singapore United States
China Mexico South Africa Vietnam
Czech Republic Netherlands
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ANN ARBOR OFFICE OVERVIEW

• Michigan Business Began in 1980
• Ann Arbor Office Opened in 1988
• 260 Skilled Personnel
W H O I S B L A C K & V E AT C H ?

• Coal Plants
• Gas Turbines
• Combined Cycle
• Gasification / IGCC
• Renewables
• AQCS
• Energy Services
• Power Delivery
• Substations
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WE UNDERSTAND THE ENTIRE LIFE CYCLE

OF A POWER PLANT
Preliminary Select Major Detailed Cost Detailed Project Outage
Feasibility Schedules Equipment Estimates Engineering Completion Management
Study Planning
W H O I S B L A C K & V E AT C H ?

Construction /
Licensing / Systems Project Soils Construction Optimization
Permitting Analysis Schedule Testing Management

Market Permitting Monte Carlo Arrangement Project Startup Monitoring / Maintenance

Assessment Support Analysis Drawings Planning & Diagnostics & Outage
Controls Services
Plant Preliminary Operator Training
System
Commercial Retirement /
Configuration Cost Definitions
Contracting Procurement Decommissioning
Study Estimates
Strategies

Feasibility / Conceptual / Definition Project

Initial Engineering Execution Operations
Engineering

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B&V ENERGY – ANN ARBOR PROJECTS

Dallman • Coal Plants

Grayling
• Gasification / IGCC
• Biomass
• Carbon Capture
W H O I S B L A C K & V E AT C H ?

• Pre-combustion
• Post-combustion
• Gas Turbines
• Combined Cycle
Mesquite • Traditional HRSG Gateway
• Solar Thermal
Hybrid
• Nuclear
• AQCS
• Wind

Black & Veatch has been involved in more megawatts of power

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generation than any other company: 121,000+ MW worldwide
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TYPES OF POWER PLANTS

OVERVI E W OF COMBI N ED CYC LE TU RBI NE TEC HN OLOGY

• Simple Cycle Combustion Turbine (Brayton Cycle)

• Coal Fired Thermal Plant (Rankine Cycle)
• Combined Cycle Plant (Brayton/Rankine)
• Cogeneration Plant

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TRADITIONAL COAL FIRED POWER PLANT

(LOW SULFUR COAL BASIS)
OVERVI E W OF COMBI N ED CYC LE TU RBI NE TEC HN OLOGY

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CWLP DALLMAN UNIT 4 (COMMERCIAL OPERATION FALL 2009)

Unit 4 – 200 MW Net with Pulverized Coal Boiler
OVERVI E W OF COMBI N ED CYC LE TU RBI NE TEC HN OLOGY

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SIMPLIFIED COMBINED CYCLE POWER PLANT

COMBINATION OF BRAYTON (GAS) AND RANKINE (STEAM) CYCLES
OVERVI E W OF COMBI N ED CYC LE TU RBI NE TEC HN OLOGY

Stack

Air Inlet

Heat Recovery Steam Generator

Turbine
Compressor Section
Section
Fuel

Combustion
Turbine
Electric Substation
Generator

Electric
Steam Generator
Turbine

Condenser
Cooling Tower

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CYCLE DIAGRAMS
9/30/2014

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MESQUITE GENERATING STATION (COMMERCIAL OP. 2003)

OVERVI E W OF COMBI N ED CYC LE TU RBI NE TEC HN OLOGY

1250 MW Net with Natural Gas Fired Combustion Turbines and Duct Burners

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GATEWAY GENERATING STATION (COMMERCIAL OP. 2009)

OVERVI E W OF COMBI N ED CYC LE TU RBI NE TEC HN OLOGY

600 MW Net with Natural Gas Fired Combustion Turbines, Duct Burners, Chillers

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MAJOR EQUIPMENT OF COMBINED CYCLES

OVERVI E W OF COMBI N ED CYC LE TU RBI NE TEC HN OLOGY

Combustion Turbines

Heat Recovery Steam Generators

Steam Turbines

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COMBUSTION TURBINES
OVERVI E W OF COMBI N ED CYC LE TU RBI NE TEC HN OLOGY

• Aeroderivatives are generally utilized for simple cycle peaking due to their
high simple cycle efficiency and low exhaust gas temperature
• New combined cycles generally utilize F, G, H, or J Class heavy duty frame
type CTGs
• F, G, H and J Class CTGs have axial exhaust and cold end drives
• F Class utilize compressor air for cooling hot components (ie, turbine blades
and transition pieces)
• G and J Class machines (MHI) utilize steam cooling (exception is M501GAC)
• Current H Class machines (GE and Siemens) do not utilize steam cooling, air
cooled

PARAMETER F CLASS G CLASS H and J CLASS

TURBINE INLET 1400 C / 2552 F 1500 C / 2732 F 1600 C / 2912 F
TEMPERATURE
(approximate)

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COMBUSTION TURBINES – TURBINE INLET TEMP (TFIRE)

OVERVI E W OF COMBI N ED CYC LE TU RBI NE TEC HN OLOGY

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COMBUSTION TURBINES
OVERVI E W OF COMBI N ED CYC LE TU RBI NE TEC HN OLOGY

COMBUSTION TURBINE
CANS EXHAUST

TURBINE
COMPRESSOR SECTION
SECTION 23
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HISTORICAL PRIME MOVERS

OVERVI E W OF COMBI N ED CYC LE TU RBI NE TEC HN OLOGY

F Class

CF
E Class Primary Suppliers
• ABB
AERO • GE
• Westinghouse
• Siemens V-Class
Early Frame

50 100 150 200

MW
1980’s to 2000’s, we saw 4 primary classes of
engines serving the U.S. market 24
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TODAY’S CT CHOICES
OVERVI E W OF COMBI N ED CYC LE TU RBI NE TEC HN OLOGY

MPS J
GE 7HA.02 Series
Siemens H
MPS G
GE 7HA.01
Alstom
CF
Siemens F5
GE 7F.05

LMS 100

LM6000

100 150 200 250 300

MW
OEMS have filled in the MW gaps, increased MW
and improved efficiency 25
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TODAY’S CT PRODUCT LINE (>850 MMBTU/HR)

OVERVI E W OF COMBI N ED CYC LE TU RBI NE TEC HN OLOGY

CT CO2, Nominal CC CO2

CT MODEL MW Efficiency 2x1
lb/MWh CC MW Efficiency lb/MWh

MPS J 327 41% 1,090 943 61.7% 724

GE 7HA.02 330 41.4% 1,079 976 61.2% 729
MPS GAC 276 39.8% 1,122 826 59.6% 750
GE 7HA.01 275 41.4% 1079 813 61.2% 729
Siemens H 274 40% 1,117 810 60.0% 745
Siemens F5EE 232 38.8% 1,152 690 58.6% 770
Alstom GT24 230 40% 1,117 664 58.4% 765
GE 7F.05 227 39.3% 1,136 688 59.5% 752

NSPS = 1000 lb/MWh for Larger CTs 26

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TODAY’S CT PRODUCT LINE

OVERVI E W OF COMBI N ED CYC LE TU RBI NE TEC HN OLOGY

Combined cycle efficiency > 61% 27

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HEAT RECOVERY STEAM GENERATORS

OVERVI E W OF COMBI N ED CYC LE TU RBI NE TEC HN OLOGY

• HRSGs are large air-to-water & steam heat exchangers

• Tube bundles include superheater, reheater, evaporator, and
economizer sections

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HEAT RECOVERY STEAM GENERATOR (HRSG)

OVERVI E W OF COMBI N ED CYC LE TU RBI NE TEC HN OLOGY

Stack
Steam Drum
Outlet Duct

Internal Insulation
and Lagging

Inlet Ducts

Expansion Joint
Economizer Section
Downcomer
Evaporator
Section
Internal Superheater
Expansion Structural Section
Joint Steel

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 OVERVI E W OF COMBI N ED CYC LE TU RBI NE TEC HN OLOGY 9/30/2014

HEAT RECOVERY STEAM GENERATOR ERECTION

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 OVERVI E W OF COMBI N ED CYC LE TU RBI NE TEC HN OLOGY 9/30/2014

HEAT RECOVERY STEAM GENERATOR ERECTION

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HEAT RECOVERY STEAM GENERATOR ERECTION

OVERVI E W OF COMBI N ED CYC LE TU RBI NE TEC HN OLOGY

Heat Transfer Module

(Tube Bundle)
Placement

Each bundle may have 12

or more tube rows

Tube to Header
Welds

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STEAM TURBINES
OVERVI E W OF COMBI N ED CYC LE TU RBI NE TEC HN OLOGY

• Startup (warm up) time requirements vary and play significant

factor in combined cycle startup times
• The steam turbine can be purchased with
the combustion turbine or can be purchased
separately
• Possible suppliers include: General Electric,
Siemens, Toshiba, Mitsubishi, Alstom,
Hitachi

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DESIGN OPTIONS FOR COMBINED CYCLES

OVERVI E W OF COMBI N ED CYC LE TU RBI NE TEC HN OLOGY

• HRSG Duct Burners for Raising STG Power

• Inlet Air Cooling (Evaporative or Chillers)
• Fuel Gas Heating
• Startup Time Considerations

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HRSG DUCT BURNERS

OVERVI E W OF COMBI N ED CYC LE TU RBI NE TEC HN OLOGY

• Duct firing raises steam turbine power output

• Utilized when grid electrical demand is high
• Duct burner sizing depends on the Customers
requirements
• Heavy Duct Firing = Duct Burner Exit Temperature 1500
to 1600 F
• Heavier duct firing results in a greater efficiency penalty

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TYPICAL COMBINED CYCLE DESIGN – DUCT BURNERS ON

OVERVI E W OF COMBI N ED CYC LE TU RBI NE TEC HN OLOGY

Design Features:
2 CTGs x 1 STG

Combustion Turbines
GE 7FA.04*

3 Pressure Reheat

Includes Duct Burners

for 43 MW or 22%
Output Boost
for Steam Turbine

Fired Condition

Light Duct Firing

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TYPICAL COMBINED CYCLE DESIGN –

DUCT BURNERS OFF
OVERVI E W OF COMBI N ED CYC LE TU RBI NE TEC HN OLOGY

Design Features:
2 CTGs x 1 STG

Combustion Turbines
GE 7FA.04*

3 Pressure Reheat

Includes Duct Burners

for 43 MW or 22%
Output Boost
for Steam Turbine

Unfired Condition

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OTHER DUCT FIRED 2X1 7FA DESIGN EXAMPLES

OVERVI E W OF COMBI N ED CYC LE TU RBI NE TEC HN OLOGY

Project   Alpha Alpha Bravo Bravo Charlie Charlie

Heat Rejection   Once Through Air Cooled Condenser Mechanical Tower
Ambient Temperature F 47 47 101 101 95 95
Duct Burners   Fired Unfired Fired Unfired Fired Unfired
  Exit Temperature F 1164   1297   1511  
Steam Turbine            
  Output MW 238.6 195.9 233.6 168.5 317.2 181.4
  Power Increase MW 42.7   65.1   135.8  
  Power Increase % 22   39   75  
  Throttle Pressure PSIA 1901 1523 1950 1361 1905 990
Plant Net Output MW 581.6 540.2 501.6 436.5 609.2 479.4
  Power Increase MW 41.4   65.1   129.8  
Net Efficiency - LHV % 55.5 56.0 51.3 52.4 51.2 54.9

 Three Separate Project Examples  Note Ambient Temperature and Heat

Rejection Differences
 Same CTG, Different Cycle Designs
 Note Change in STG Throttle Pressure from
 Light Firing Increased STG Output 22%
Unfired to Fired Condition
 Heavy Firing Increased STG Output 75%  Sliding STG Inlet Pressure
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INLET AIR COOLING (EVAPORATIVE TYPE)

OVERVI E W OF COMBI N ED CYC LE TU RBI NE TEC HN OLOGY

• Combustion turbine inlet air cooling raises CTG

power output
• Evaporative coolers are relatively inexpensive, but
consume water
• Incorporated into the inlet air filter housing by the
CTG OEM
• Evaporative coolers are most effective in arid
climates, but are frequently included in plant
designs for all types of climates

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INLET AIR COOLING (CHILLER TYPE)

OVERVI E W OF COMBI N ED CYC LE TU RBI NE TEC HN OLOGY

• Chillers are expensive, but yield greater CTG power output

increase
• Typically sized to reduce CTG inlet air temperature to 50 F from
some specific ambient condition
• Typically water is a byproduct, condensed from the ambient air,
and can be utilized elsewhere within the power plant
• The chilling heat transfer coil is integrated into the inlet air filter
housing by the CTG OEM
• Chilling system designs vary, particularly the fluid passing through
the coil that chills the ambient air (typically chilled water)
• Refrigerant types: anhydrous ammonia, R-123, etc
• Unlike evaporative coolers, inlet air chillers yield an efficiency
penalty
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INLET AIR CHILLED 2X1 7FA DESIGN EXAMPLE

OVERVI E W OF COMBI N ED CYC LE TU RBI NE TEC HN OLOGY

Project   Bravo Bravo Bravo Bravo

Heat Rejection   Air Cooled Condenser

Ambient Temperature F 101 101 101 101

Chiller Status   On Off On Off

Duct Burners   Fired Fired Unfired Unfired

  Exit Temperature F 1238 1297    

Steam Turbine          

  Output MW 234.4 233.6 176.9 168.5

  Throttle Pressure PSIA 1950 1950 1424 1361

Plant Net Output MW 553.9 501.6 496.4 436.5

  Power Increase MW 52.3   59.9  

Net Efficiency - LHV % 51.0 51.3 51.8 52.4

 Chiller primarily increases CTG power  STG power increase is due to increased CTG
exhaust energy to the HRSG
 STG power is increased if it is not already at
maximum output due to duct firing  Chiller operation yields slight efficiency
penalty
 If STG was already fired to the maximum,
duct firing is reduced
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FUEL GAS HEATING

OVERVI E W OF COMBI N ED CYC LE TU RBI NE TEC HN OLOGY

• Fuel gas heating increases the efficiency of the combined

cycle
• Low grade heat from the HRSG is used to pre-heat the fuel
gas which improves combustion turbine heat rate
• The heated fuel gas temperature will depend on the CTG
OEM
• Values between 280 F and 365 F are common
• The temperature must be controlled to a stable set point or
the CTG will run back or trip
• Typically feed water from either the LP drum (280 F) or the
IP economizer exit (365 F) is utilized to heat the fuel gas

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STARTUP TIME CONSIDERATIONS

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Startup times are an increasingly important consideration for

combined cycles due to the following:

• Startup emissions are often limited by air permits

• Agencies understand startup emissions can be minimized
• Faster startups consume less fuel and thus save the Owner money
• Fast startups allow the operator to hit higher outputs faster,
increasing revenue for merchant generators
• Combined cycles will increasingly be required to start and/or
change loads quickly as wind turbine farm output and/or solar
energy output to the grid varies

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CHANGING SYSTEM DYNAMICS

Impact of wind generation on power system load

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• Wind is intermittent and is a major contributor during low load hours, but only
minimal during peak load hours
• Wind generation requires a generation mix with more operational flexibility to
serve the net load
Addition of wind generation:
Wind generation has Net Load Duration Curve
small (but not zero) becomes more steep
impact on peak load Hydro

Gas GT

Peaking
Peaking
Generation
Generation
System Load

Mid-Merit Gas CCGT

Mid-Merit
Generation
Generation

Base Load
Generation Base Load
Generation

Hours of Operation / Year

Wind generation has major
System Load without wind impact on low and minimum
Net System Load with wind load conditions Clean Coal 44
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AIR QUALITY CONTROL FOR COMBINED

CYCLES
OVERVI E W OF COMBI N ED CYC LE TU RBI NE TEC HN OLOGY

New large combined cycles in the United States typically include

the following air quality control equipment and features:
• Dry Low NOx burners for the CTG
• Selective Catalytic Reduction (SCR) system in the HRSG for NOx
reduction
• Ammonia injection for the HRSGs SCR
• Carbon Monoxide (CO) catalyst in the HRSG for CO and VOC
reduction

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HOW DOES AN ENTRY-LEVEL MECHANICAL ENGINEER

GET INVOLVED?
OVERVI E W OF COMBI N ED CYC LE TU RBI NE TEC HN OLOGY

System Engineer Pipe Stress Engineer

• Development of system P&ID’s • Modeling of piping systems
• Service/Potable Water • Pipe materials, temperatures &
• Station Air pressures
• Compressed Gases • Model supports
• Wastewater Collection • Thermal growth
• System and equipment sizing • Wind & seismic activity
calculations • Verify design meets equipment
• Centrifugal/Vertical Sump Pumps and code allowables
• Air Compressors/Dryers • Pipe support detail drawings
• System Piping • Anchors, rod hangers, springs,
• Development of technical struts & shock absorbers
specifications for equipment
• Pumps/Compressors
• Valves/Miscellaneous Piping
Devices

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 OVERVI E W OF COMBI N ED CYC LE TU RBI NE TEC HN OLOGY

WHAT IS A P&ID?
9/30/2014

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 OVERVI E W OF COMBI N ED CYC LE TU RBI NE TEC HN OLOGY

WHAT IS A PIPING ISOMETRIC?

9/30/2014

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PIPE STRESS ANALYSIS

9/30/2014

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CAREER RELEVANT COURSEWORK

OVERVI E W OF COMBI N ED CYC LE TU RBI NE TEC HN OLOGY

System Engineer Pipe Stress Engineer

• Major Required: • Major Required:
• Thermodynamics • Materials Science & Engineering
• Fluid Mechanics • Statics
• Heat Transfer
• Electives
• Electives • Intermediate Mechanics of
• Intro to Combustion Deformable Solids
• Energy Conversion • Computer Aided Design of
• Computer Assisted Design of Structures
Thermal Systems • Finite Element Analysis
• Design of Alternative Energy
Systems

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