Fast cycling and rapid start-up:

new generation of plants

achieves impressive results
Reprint from:
Modern Power Systems, January 2011

Author:
Lothar Balling, Siemens AG,
Erlangen, Germany

Answers for energy.

 COMBINED CYCLE

Fast cycling and rapid start-up:

new generation of plants
achieves impressive results
In last months issue an analysis of the operational characteristics of various power generation technologies
(pp 61-65) concluded that modern combined cycle power plants, with cycling and fast start capabilities, have
a number of advantages in a grid where a large percentage of renewables is envisaged, as in Germany, for
example. In this second article the theme of combined cycle plant operational flexibility is explored further.
Recent innovations in combined cycle technology are described, as well as newly commissioned power plants
that demonstrate what can be achieved.

Figure 1. Recent combined cycle projects with enhanced flexibility and fast start capabilities
Lothar Balling, Siemens,
Erlangen, Germany

he increased use of combined cycle

T plants for power generation over the

past decade can be attributed to their
high efficiencies, short execution times
and relatively low investment costs. But now
their potential for cycling and fast start-up is
becoming an increasingly important selling
point.
This need for increased flexibility first Pont sur Sambre, France Sloe Centrale, Netherlands
emerged at the end of the 1990s in the United
States and the United Kingdom. The price of
fuel continued to rise due to the large number
of plants being built during the boom. Plants
initially planned to have a base-load role were
shifted to the load regime of an intermediate-
load plant.
The challenge presented to projects by this
changed requirement gave birth to the idea of
trying to improve plant flexibility without
compromising plant service life or plant
efficiency.
As the market continued to develop, a Marchwood, England Pego, Portugal
demand for quicker start-ups soon followed
the demand for more frequent start-ups. This
market demand finally resulted in the launch
by Siemens of a development project called
FACY (FAst CYcling), which combined all
the initial engineering ideas into a single
integrated plant concept. The aim of the
resulting R&D programme was to design a
plant for an increased number of starts and to
reduce start-up times. If possible, no limits
were to be placed on the gas turbine by other
power plant components, such as the heat
recovery steam generator or steam turbine, Enecogen, Netherlands Hemweg and Diemen, Netherlands
during hot and warm starts.
In the course of the project, potential areas
came to light where further optimisation could until certain steam parameters have been While the first generation FACY reduced
be achieved, although these had to wait for a reached were eliminated as part of the start-up times for a hot start from 100 to 55
second development generation to be shortened Start on the Fly start-up minutes, the second generation succeeded in
implemented. procedure. In this procedure, the steam pushing start-up times down below the 40
The major improvement offered by this turbine is started up in parallel to the gas minute mark.
second generation involved the start-up turbine using the first steam which becomes The first plants incorporating the features of
procedure. Hold points at which a plant waits available after a hot start. both the first and second generations of the

2 www.modernpowersystems.com January 2010 Modern Power Systems

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operation (Figure 1). plants, such as combined cycle units, are The idea of focusing plant design on an
A good example is Sloe Centrale, a 2 x 430 required in order to compensate for increased number of fast starts originated
MW F-class single shaft plant in the fluctuating renewables. The requirements from market conditions and from specific
Netherlands, where 30-minute start-up with respect to grid support, which are usually projects. A multidisciplinary team of
times were recorded during acceptance tests, defined in a country-specific grid code, have component and plant experts (for the steam
while achieving over 59% net efficiency. recently become more rigorous for this reason. turbine, gas turbine, balance of plant and
Equally good results have been exhibited by Some of the most stringent requirements are auxiliary systems, I&C and steam generator)
other newly commissioned plants. This to be found in the UK grid code. Requirements was formed by Siemens around 2002 to
means that the second generation of FACY in the areas of load stabilisation at low identify improvement potential in the existing
has far surpassed expectations in a number frequencies, primary and secondary frequency plant concepts.
of cases. response, and island operation capability have The team identified the following priorities:
Shortening start-up times and improving presented a particular challenge to UK Maintaining pressure and temperature in
starting reliability while increasing the operators for quite some time. However, the the main components during shutdowns, by
number of starts was only one of many new recently handed over 840 MW multi-shaft F- using stack dampers, auxiliary steam, etc.
requirements with respect to plant flexibility. class Marchwood plant has finally Ready-for-operation water/steam cycle
An increasingly important driver (as demonstrated that the problem can be solved using a fully automated start-up concept
discussed in last months article) is the growing without compromising efficiency (over 58%) without manual operation or intervention
percentage of renewables envisaged on the by introducing additional technical features during hot start.
grid (see Figure 2). Wind and solar energy are and optimising the plant concept. Optimised component design (eg, high
not continuously available and difficult to A decisive factor in the success of Marchwood capacity and fast acting de-superheaters)
predict precisely. Reserve power generating was the integrated approach, which combined and plant operation to reduce material
capabilities must therefore be provided which the potentials of several systems and fatigue caused by load cycling.
can be activated quickly. Gas turbine based components in a single solution, including use Flexible operation concept to allow the
plants are an obvious choice here as they can of gas turbine compressor optimisation, firing operator to predetermine component
be started up at relatively short notice. The reserves, fast wet compression and other fatigue and to choose start-up time and
inherent inertia of other types of power measures, combined with an optimised ramp rate.
generating facilities is usually much greater, I&C/closed-loop control concept. Optimisation of the automation and control
making them largely unsuitable for use as a The new demand for extremely fast power concept.
rapidly available reserve source of power. generating availability is also becoming New start-up sequence, Start on the Fly,
There are, of course, other fast-responding apparent in CCGT developers economic to allow a nearly unrestrained ramp-up.
sources of power such as pumped storage. But assessments. Only a few years ago there were Figure 3 summarises the main features of the
they do not provide enough capacity to cover projects in which start-up times did not FACY concept. These measures help reduce
the renewable generating capacity in the figure at all in the assessment, whereas now start-up time significantly. They are modular
European grid system, with the prospect of we are seeing over 100 000 /min for some and are offered, configured and implemented
30% renewables by 2030. projects. on a project-specific basis.

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bring the water/steam cycle within specified of the HRSG.
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In a conventional HRSG the high pressure optimised high-
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in the start-up and ramping procedure. As a superheater to limit steam temperatures
thick-walled component it is exposed to large during the start-up, has been developed for
temperature gradients and high operating warm and cold starts. This reduces thermal
pressures. Thermal stress in the high-pressure stress in critical components of the steam
drum walls limits the load-, start up- and shut turbine.
down- gradients of the HRSG.
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a Benson-type boiler, so these limits do not There are essentially two ways in which
apply. The Benson boiler technology automation system is optimised to support
employs once-through steam generation, improved start-up:
which means that conventional separation of Design limits are fully exploited through the
steam and boiling water inside a drum is not use of closed-loop control instead of earlier
necessary. Instead, steam is generated empirically based approaches. A turbine
directly within the evaporator tubes, as stress controller is used to determine
shown in Figure 4. thermal stress based on temperature
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number of permissible starts and cycling turbine and ensures that stress limits are not
events during the plant lifetime to exceeded. The turbine stress controller
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depending on such factors as current
electricity market prices. Maintenance
intervals can be extended using the COST
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mode permits controlled fast start-up, but
entails increased maintenance
requirements.
The start-up procedure is automated to a level
that enables hot starts with only a few operator
actions, the aim being to minimise inefficient
and unproductive periods during start-up
preparations. Draining and venting are largely
automated, for example.
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In addition to the features included in the
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parallel start-up of gas and steam turbines has
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controlling the temperature gradients within most stringent requirements imposed on plant output can be compensated for by rapidly
limits acceptable for all critical plant dynamics are to be found in the grid code of opening the guide vanes on the compressor.
components and on long term turbine the UK, reflecting its island geography. Three The fuel flow is increased at the same time.
operating experience over a range of steam of the most critical considerations are: load This can compensate for a drop in power of
conditions. The new concept enables the plant stabilisation at low frequencies; primary and around 6 MW.
to be started-up without any gas turbine load secondary frequency response; and island In unfavourable operating conditions,
hold points, enabling a new start-up sequence operation capability. however, this increase in output will not be
to be implemented see Figure 5. The main sufficient on its own. In this case Fast Wet
innovation is the early steam turbine starting Load stabilisation at low frequencies Compression (a patented Siemens concept)
point with earlier acceleration and loading of Normal fluctuations in the balance between can be used to mobilise a further power
the turbine. generation and consumption are reflected in reserve of around 12 MW.
fluctuations in grid frequency which can be Fast Wet Compression consists of spraying
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implemented in plants across Europe and can, however, also decrease or even increase the mass flow through the compressor. The
excellent results have been achieved in single significantly in the event of unusually large evaporating water also cools the air flow at
shaft as well as in multi shaft configurations. disturbances. the compressor inlet. The air density and
Two notable examples are the Pont sur Sambre Unfortunately a decrease in grid frequency consequently the mass flow through the
F-class single shaft plant in France and the F- also means a reduction in turbine speed and compressor increase due to this cooling
class multi shaft configuration at Irsching 5 in subsequently a decrease of power output. This process. Rapid activation of the system
Germany, Figures 6 and 7, respectively. decrease in speed causes the compressor in a constitutes a challenge to control systems, as
Both units have demonstrated the capability gas turbine to produce a reduced volumetric the fast increase in power output requires
to start-up and reach full load in about 30 flow, thus decreasing gas turbine output if perfect co-ordination between the gas
minutes folowing an overnight shut down, appropriate compensatory measures are not turbine control system and the water
without compromising efficiency, achieving implemented. injection.
levels of over 58% and over 59%, respectively. The United Kingdom grid code stipulates These grid support features have been
It is noteworthy, that the single shaft that power output must be maintained for a validated and demonstrated in the
operating concept allows parallel start up of minimum of 5 minutes in the event of a Marchwood F-class multi shaft plant in the
several units at a site, resulting in multiples of, frequency drop, down to 49.5 Hz so as to UK, at a power output of about 840 MW and
eg, 430 MW, being available in around 30 avoid further taxing of the grid due to under- over 58% efficiency (Figure 9).
minutes, as has been demonstrated at Sloe frequency. If a greater decrease in frequency Plots from the Marchwood tests are shown
Centrale, with its two units. occurs, the grid code permits a maximum in Figure 10. It can be seen that an 18 MW
decrease in output of 5%, down to 47 Hz, as increase was achieved (for each gas turbine)
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minimum requirements for power plant several measures for increased output can be the requirement of the United Kingdom grid
dynamics are set out in grid codes. Some of the implemented at short notice. The decrease in code.

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The purpose of load stabilisation at low
frequencies is to prevent further
destabilisation of the grid when the frequency
decreases due to major disturbances. Primary
and secondary frequency responses are now
required for grid support during normal
operation. For this purpose the UK grid code
stipulates that a power plant operating at part
load must be capable of making additional
power available. Figure 11 illustrates the
relevant part of the UK grid code. We can see
that a power plant operating at under 80%
load must be able to make available at least
10% of its rated power within 10 seconds in
the event of a decrease in frequency. For
secondary frequency response 10% of its rated
power must be made available within 30
seconds. Figure 11 shows that the
requirements are reduced when the plant is
operating at loads over 80%.
Unlike load stabilisation at low frequency,
there is no need to look for a further power
reserve in this case. The challenge lies more in
the speed at which the power must be made
available.
To meet the requirements of the grid code,
we rely on fast repositioning of the compressor
IGVs coupled with fuel control optimised to
such an extent that load ramps are possible
without destabilising combustion.

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Figure 12 illustrates the results of tests done smaller than 55% of rated power in this case.
on the Marchwood plant and clearly shows This load reduction must be effected
that the required additional power is achieved sufficiently quickly that the island frequency
both after 10 seconds and after 30 seconds. In remains below 52 Hz. Grid studies based on
fact, performance is significantly better than the UK National Grid requirements show that
that required by the grid code in both the load reduction must take place within
instances. around 8 seconds.
Another aspect of the grid code, also shown The power plant must detect island
in Figure 11, is high frequency response, formation automatically and take immediate
namely that load must be reduced by 10% of action. As soon as island operating mode is
rated power within 10 seconds in the event of activated, permitted load change ramps are
over-frequencies of up to 500 mHz. However, set to the maximum value. The inlet guide
when it comes to load reduction the island vanes in the gas turbine compressor are
operation requirement (see next section) is closed without delay. At the same time the
even more stringent. various closed-loop controls ensure that the
power is decreased at the maximum rate of
Island operation capability change for load. Maintaining flame stability
The primary objective of island operation and avoiding potential flash backs in the
capability is to stabilise the grid, in the event combustion system are the main objectives
of excess power and an abrupt drop in of closed-loop control optimisation, so
consumption within an islanded portion of the as to avoid emergency shutdown of the
grid, resulting in a very rapid frequency gas turbine.
increase. The power plant must react to this Figure 13 illustrates an island operation test
frequency increase by throttling back to at Marchwood. The gas turbine output was
stabilise the frequency, thus avoiding a forced decreased by 52% within 4 seconds as the result
shut-down due to over-frequency. of a simulated fast frequency increase of 0.9
Uncontrolled shut-down of power plants Hz, without initiating a plant trip. A further
can result in a grid collapse, which is why the decrease of 4% was achieved in the following
UK grid code stipulates that power plants 4 seconds. Thus performance again exceeded
must be capable of rapidly decreasing from grid code requirements.
rated power to the design minimum operating
level (DMOL). The DMOL must not be Transfer to the H
Meanwhile, these basic plant features
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highest efficiency technology is capable of
supporting the same stringent grid code
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ca. 380 MW  The previous sections clearly demonstrate that
FACY and Start on the Fly permit a reduction
in start-up times as well as an increased
 number of start-ups, enabling nightly power
60 % / 225 MW load 60 % / 225 MW load plant shut-downs. The latter offers two
reduction in < 1 min. increase in < 1 min. additional benefits:

Carbon dioxide emissions are minimised by
shortening inefficient plant start-ups.
Active Maximum electrical efficiency is reached
power faster and total emissions are reduced.

Since nightly shutdowns and reliable start-
ups become economically feasible, overall
carbon dioxide emissions are further
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the Fly for a hot start offers an estimated Gas consumption (t) CO2 emission (t) and start up ()
added value of more than 3 million euros 
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when the load decreases, so does overall power plant operator with an additional individual countries. No monetary valuation
efficiency, meaning that gas and carbon economic benefit for every start. of the additional plant flexibility is included in
dioxide costs can only be reduced Figure 16 shows the carbon dioxide and fuel tender specifications as yet. For this reason
disproportionately. savings which can be achieved by night-time todays plants are designed purely based on
In addition to the positive effect of load shutdown using FACY compared with night- grid code specifications. Depending on the
reduction, shutting a power plant down at time part-load operation at about 25%. We level of electricity market liberalisation,
night can achieve other significant benefits. can see that the power plant in this example however, the various flexibility features enable
Only shut-down and start-up costs are can avoid up to 130 tons of gas consumption additional earnings to be generated, in
incurred, for example. Restrictions relating to and 362 tons of carbon dioxide emissions per particular by participating in the frequency
the permitted number of start-ups for the plant night through night-time shutdown. This reserve market.
have been significantly reduced, thanks to the increases the annual power plant profit by 4.8 Another potential benefit is that plants with
FACY programme. FACY and Start on the million euros as compared with night-time high reliability and operational flexibility,
Fly have also significantly reduced start-up part-load operation. able to cope well under disturbed grid
times. The result is lower gas consumption and Today grid support features arise primarily conditions, can expect to be prioritised for
lower carbon dioxide emissions, providing the from the grid access requirements of the dispatch. MPS

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PWFSOJHIU
TIVU
EPXO
8JUI
'BTU
8FU
$PNQSFTTJPO
BOE
PUIFS
GFBUVSFT
UFTUT
BU
4FWFSO
IBWF
JOEJDBUFE
UIBU
JUT
QFSGPSNBODF
JO
UFSNT
PG
6,
HSJE
DPEF
TVQQPSU
JT
BU
MFBTU
BT
HPPE
BT
UIBU
PG
.BSDIXPPE
TFF
QQ


5IF
QMBOUT
IJHI
EFHSFF
PG
PQFSBUJOH
GMFYJCJMJUZ
BMTP
NFBOT
UIBU
JU
JT
DBQBCMF
PG
WFSZ
RVJDLMZ
DPNQFOTBUJOH
GPS
UIF
GMVDUVBUJOH
GFFEJO
GSPN
XJOE
UVSCJOFT
6TF
PG
BO
BJSDPPMFE
DPOEFOTFS
JOTUFBE
PG
B
DPPMJOH
UPXFS
BOE
BQQMJDBUJPO
PG
BO
JOOPWBUJWF
XBTUF
XBUFS
DPODFQU
BMTP
NJOJNJTFT
XBUFS
DPOTVNQUJPO
&GGJDJFODZ
JT
BCPVU

BOE
UIBOLT
UP
BEWBODFE
CVSOFS
UFDIOPMPHZ
UIF
QMBOUT
OJUSPHFO
PYJEF
FNJTTJPO
MFWFMT
BSF
WFSZ
MPX
BSPVOE

QQN
*O
UFSNT
PG
IFBMUI

TBGFUZ
EVSJOH
DPOTUSVDUJPO
UIF
QSPKFDU
IBT
BMTP
CFFO
FYFNQMBSZ
DMPDLJOH
VQ
NPSF
UIBO
UISFF
NJMMJPO
XPSLJOH
IPVST
XJUIPVU
B
MPTU
UJNF
BDDJEFOU
XJUI
PWFS

XPSLFST
PO
UIF
TJUF
BU
QFBL
UJNFT

- 50%
Power / frequency in 4s
Primary frequency response: Power / frequency
Primary Secondary )[
resp. response r
'SFRVFODZ


N)[ 
.8
.8 )[ r
3FRVJSFE
MPBE
NJO
T 

Island operation:
-PBEJOH
CZ r
"DIJFWFE


.8
BQQS



.8   r
3FRVJSFE
7FSZ
GBTU
MPBE
SFEVDUJPO

-PBEJOH
CZ  PG
BU
MFBTU

PG
SBUFE
$$
QPXFS
 
.8  XJUIPVU
USJQ
USJHHFSFE
CZ

 
 N)[
Secondary frequency response: 
  4UBCMF r
"DIJFWFE
+PJOU
SFEVDUJPO
PG
(5
BOE
 r
'SFRVFODZ


N)[ 'SFRVFODZ EFMPBEJOH 45
PG
BQQSPY

PG
SBUFE
$$
 
 r
3FRVJSFE
MPBE
NJO
T  JODSFBTF
CZ

.8 QPXFS
XJUIJO

T
'SFRVFODZ 
N)[
 EFDSFBTF
r
"DIJFWFE


.8
BQQS


r
#PUI
UVSCJOFT
SFNBJO
JO
TUBCMF

N)[  
PQFSBUJPO
GPS
IJHIFTU
GMFYJCJMJUZ
 



1MVT r
'PS
TJOHMF
TIBGU
POMZ
QPTTJCMF
XJUI

  .JOVT JOUFHSBUFE
(U
BOE
45
DPOUSPM
 TPMVUJPO

 Time
Time  



































3FTVMUT
PG
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7
This article appeared in:
Modern Power Systems
January 2011, Page 3541
Copyright 2011 by
Modern Power Systems

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