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Combined Cycle Development Evolution and Future GER4206 PDF
Combined Cycle Development Evolution and Future GER4206 PDF
GER-4206
GE Power Systems
Combined-Cycle
Development
Evolution and Future
David L. Chase
GE Power Systems
Schenectady, NY
Combined-Cycle Development Evolution and Future
Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Gas Turbine Combined-Cycle Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Gas Turbine Combined-Cycle Development . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
First Generation Combined-Cycle Plants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Second Generation Combined-Cycle Plants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Third Generation Combined Cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fourth Generation Combined-Cycle Plants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
wide range of fuels, ranging from clean models, enabling high efficiency
natural gas and distillate oil fuels to ash- operation at part load through reduction
bearing crude oil and residual oil fuels. in turbine airflow. This is accomplished
Operation with coal-derived gas fuels has at nearly constant turbine exhaust
been applied in many commercial-size, temperature, so that design steam
combined-cycle systems. conditions and low stack loss can be
4. Flexible Duty Cycle - Combined-cycle maintained to provide excellent part-load
systems provide flexibility in operation efficiency.
for both baseload and mid-range duty 5. Short-Installation Cycle - Combined-
with daily startup. Gas turbines in multi- cycle plants can be installed and
shaft, combined-cycle configuration can operated in less time than that required
be started quickly, bringing about two- for conventional steam plants. Again, this
thirds of plant power on-line, typically in is primarily due to the pre--engineering
systems as single or multiple gas turbine tion in 1952. The heat recovery economizers
and HRSG installations can provide from applied in these systems used bare tubes, as was
about 50 MW to several thousand typical of heat exchangers in combined-cycle
megawatts of power generation at systems installed prior to 1959.
essentially constant plant thermal
Most combined-cycle power generation systems
efficiency.
installed during the 1950s and early 1960s in-
cluded conventional-fired boilers. These sys-
Gas Turbine Combined-Cycle
tems were basically adaptations of conventional
Development steam plants with the gas turbine exhaust gas
The commercial development of combined-cy- serving as combustion air for the boiler. The
cle systems has proceeded in parallel with gas efficiency of this type of combined cycle was
turbine development. We are presently in the approximately 56% higher than that of a simi-
third generation technology of combined-cycle lar conventional steam plant. These systems
systems and are at the launch point of the could economically utilize bare tubes in the
fourth generation. boiler because of the high mean temperature
difference between the combustion products
First Generation Combined-Cycle Plants
and the water/steam.
The first gas turbine installed in an electric util-
ity in the United States was applied in a com- The repowering of steam power plants with gas
bined cycle. This was a 3.5 MW gas turbine that turbine generators and HRSGs is still attractive
used the energy from the exhaust gas to heat in many applications today as evidenced by the
feedwater for a 35 MW conventional steam unit. recent Colorado Public Service, Fort St. Vrain
The gas turbine is shown in Figure 6. A schemat- installation, which was placed in commercial
ic showing the combined-cycle system is shown operation in 1999.
in Figure 7. This system entered service in June The summary presented in Table 1 characterizes
1949, and a similar system was added to this sta- the first generation combined-cyle systems.
BOILERS
STEAM STEAM
TB TB
GAS GAS
TB TB
GEN GEN
STACK G G
COND COND
G.T.
EXHAUST
LP
FEEDWATER
HEATER
HEATERS
BF PUMPS
Figure 7. OG&E Belle Isle feedwater heating repowering system cycle diagram
Second Generation Combined-Cycle the first generation systems. Table 2 and Table 3
Plants represent second generation characteristics and
experience.
Equipment that made it economically feasible
to weld continuous spiral fins to tubes was intro- The requirements for stack gas NOx emission
duced to boiler manufacturers in 1958. Heat control was initially legislated during the late
recovery combined cycles, using the sensible 1970s. The first systems utilized gas turbine
heat in the gas turbine exhaust gas, were made water or steam injection to meet new source
feasible by the enhanced gas-side heat transfer performance standards of 75 ppmvd at 15%
using finned tubes. Combined-cycle systems oxygen with efficiency and fuel-bound nitrogen
with finned tube boilers entered service in adjustments. Combined-cycle plants utilized
1959. steam from the steam cycle for NOx control
because this had the least impact on plant effi-
During the 1960s the application of the heat
ciency. As emission requirements became more
recovery type of combined-cycle systems
stringent, it was necessary to apply SCR to aug-
became more prevalent. Its initial application
ment NOx abatement (TEPCO Groups I and
was in power and heat applications where its
II). Application of SCR systems became com-
power-to-heat ratio was more favorable. Also, a
mon in Japan and in the USA in the mid-1980s.
small number of the heat recovery type com-
bined cycles were installed in utility power gen- Third Generation Combined Cycles
eration applications during the 1960s.
The first and second generation combined-
Application of these systems in the 1970s and
cycles were configured using gas turbine
1980s established the heat recovery feedwater
designs that were optimized for simple-cycle
heating combined-cycle as a mature technology
output and efficiency. Gas turbine design opti-
for baseload and mid-range service.
mization for simple-cycle and for combined-
The summary presented in Table 1 characterizes cycle output and thermal efficiency is illustrated
The GE F Technology gas turbine designed in The fleet leader F Technology gas turbine
the 1980s, with pressure ratio of about 14:1 and entered commercial operation in 1990 in a
2400F firing temperature was the result of a combined-cycle installation at the Virginia
design effort aimed at optimization for com- Power Chesterfield site and launched the third
bined-cycle peak efficiency rather than simple- generation of combined-cycle systems.
cycle peak efficiency.
The third generation F Technology com- 3. Application of reheat steam cycle with
bined-cycle experience is summarized in Table 4 F Technology gas turbines.
and system characteristics are defined in Table 5. The current STAG product line ratings, which
The trend of combined-cycle plant efficiency represent third generation combined-cycle
improvement is illustrated by Figure 9, which capability, is summarized in Figure 10.
shows the performance of selected STAG plant
installations as a function of commercial oper- Fourth Generation Combined-Cycle Plants
ating date. Gas turbine development has had Further gas turbine materials development and
the greatest impact on improved combined- hot gas path cooling technology advances, as
cycle efficiency due primarily to the increase in well as higher temperature and pressure steam
firing temperature made possible through the cycles, will continue the trend for more efficient
development of high-temperature oxidation/ combined-cycle systems in the future.
corrosion-resistant metals and coatings, and
Gas turbines installed in the first, second and
advanced metal surface cooling techniques.
third generation combined-cycle plants are con-
Another important factor is that the gas turbine
figured with open-loop cooling of the turbine
contributes about two-thirds of the combined-
hot gas path and cooling air supplied from the
cycle plants power.
compressor. Hot gas path components are in
Advances in steam system technology have also large part cooled by film cooling. As a result,
contributed to improved combined-cycle effi- there is significant exhaust gas temperature
ciency. The significant steam-cycle develop- drop across the first stage nozzle, and signifi-
ments include: cant chargeable air required to cool down the
1. Technology to weld continuous spiral steam turbine stages. The drop in exhaust gas
fins on HRSG heat transfer tubes temperature across the first stage nozzle and
(1959). the increase in chargeable cooling loss due to
2. Application of larger annulus area increases in turbine firing temperature may
steam turbine designs for low exhaust diminish efficiency gains to the point of being
pressure applications. uneconomical. For this reason, the GE fourth
Combined-Cycle Illustration
1. City of Clarksdale (S105)
2. Houston L&P, Wharton Station (S407B)
35
(1)
30
1970 1980 1990 2000
Plant Commercial Operation Date
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
Net Efficiency (percent LHV)
generation plants with H Technology gas tur- technology is expected to provide two percent-
bines will be configured with an integrated age points thermal efficiency improvement.
closed-loop steam cooling system (See Figure 11).
The H platform gas turbine combined-cycle
This system allows higher turbine firing tempera-
plants are expected to achieve 60% LHV thermal
ture to be achieved without increasing combus-
efficiency in the first half of this decade. The
tion temperature. This is because exhaust gas
application of ceramic hot gas path parts and
temperature drop across the first stage nozzle is
coatings show promise for further future per-
significantly reduced as outlined in Figure 12.
formance gains.
Another important benefit of the integrated
closed-loop steam cooling system is the elimina- Steam cycle improvements that include
tion of chargeable cooling air for the first and increased steam pressure and temperature with
second stage rotating and stationary airfoils. This supercritical steam cycles have near-term applica-
Fue l
H e at Re c ov e ry
Fu el
S te a m G e ne r ato r
He a tin g
S ys te m
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
F e ed w a ter
HP IP LP LP G en er a tor Pu m p
G a s Tu rb in e S te a m Tu rb in e
L E G E ND
C oo lin g Deaerating
S te a m W a te r Condenser
A ir T re atm en t
W a te r
E x ha u s t Filter
Air A
Fu e l G la n d S ea l
Ai r Filter Co nd e n se r
B
Co nd en sa te P u m p
C on de ns a te Fil te r
tion. Current economic analysis indicates, how- As in the past, operating cost (fuel price) and
ever, that the thermodynamic gain associated the cost of new technology development will
with steam cycles that have steam temperatures dictate the trend for increased combined-cycle
and pressures above the current levels (1050F efficiency.
and 1400 PSIG to 1800 PSIG) cannot be justi-
fied in most cases because of the added costs.
References
D.L. Chase and P.T. Kehoe, Combined-Cycle Product Line and Performance, GER-3574F.
C.E. Maslak and L.O. Tomlinson, Combined-Cycle Experience, GER-3651E.
H.E. Miller, F Technology - The First Half Million Operating Hours, GER-3950.
Frank Brooks, GE Heavy-Duty Gas Turbine Performance Characteristics, GER-3567G.
P.W. Schilke, Advanced Gas Turbine Materials and Coatings, GER-3569F.
J. Cofer, J.K. Reinker and W.J. Sumner, Advances in Steam Path Technologies, GER-3713D.
D.L. Chase and L.B. Davis, Current Review of Combined-Cycle Technology - Pacific Coast Electrical
Association, 1988.
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