Professional: October 2017 DR - Hans-Peter Wolf

Modelling of Combined Cycle
Powerplants
with
®
EBSILON Professional
October 2017
Dr.Hans-Peter Wolf
Stepwise introduction into modelling of gas
turbine process and heat recovery boiler (HRSG)
• Gas turbine process using individual components

• HRSG 1-pressure
• HRSG 2-pressure
• HRSG 3-pressure
• Reheat
• Separation of superheat and reheat
• HRSG and steam turbine in Ts – diagram
• Superheat of IP and LP steam
• HRSG in QT - diagram
• Water injections
• Auxiliary burner
• VTU Gas turbine library for a particular gas turbine
• Alternative heat exchanger components
• EbsWizard
October 2017 Modelling of Combined Cycle Power Plant with EBSILONProfessional 2
Exercise, Step 1
Modelling of Gasturbine
Modelling of gasturbine with Ebsilon-components

- compressor (comp. 24)
- Combustion chamber (comp. 22)
- Turbine (comp. 23)
(detailled Modelling using VTU Gasturbine library -> Exercise, Step 10)
Exercise, Step 2,
Adding a HRSG (1-pressure)
Modelling of HRSG with components

- Heat exchanger (comp. 26) for superheater and economizer
- Evaporator with drum (comp. 70)
Exercise, Step 2,
Explanations
The recommended procedure for configuration of components :
• Superheater :
- Specification of steam outlet temperature (measurement)
- FTYPHX = „Superheater“
- FSPECD = „both cold stream and one hot stream temperature“
• Evaporator (with drum) :

- FSPECD = „specification of pinchpoint PINPN“
- PINPN = 5K (default value)
- FTAPPN = „by specification value TAPPN“
- TAPPN = 3K (default value)
• Economizer :
- FTYPHX = „Economizer“
- FSPECD = „both cold stream and one hot stream temperature“

Exercise, Step 2,
Explanations
Alternative Procedure for configuration of components

(if no heater outlet temperatures and Terminal Temperature
Differences are known):
• Superheater :
- FSPECD = „Effectiveness Method“
- EFF = 0.8 (default value)
• Evaporator (with drum) :

- FSPECD = „Effectiveness given as EFF“
- EFF = 0.96 (recommended value)
- FTAPPN = „T1 given externally“
• Economizer :
- FSPECD = „Effectiveness Method“
- EFF = 0.8 (default value)

Exercise, Step 3,
2-pressure HRSG
- Splitting the turbine into HP and LP turbine

- LP drum supplies steam to LP turbine

Exercise, Step 4,
3-pressure HRSG
- Splitting the turbine into HP-, IP- and LP-turbine

Exercise, Step 4,
3-pressure HRSG in Ts-diagram
XX< 0.9
Challenge: steam quality at LP turbine outlet too small

(same with 1- and 2- pressure HRSG at same steam parameters)
Exercise, Step 5,
Reheat
- Steam leaving HP turbine is heated again

- As a consequence in Ts-diagram the turbine-expansion is
shifted to the right (-> higher steam quality)
Exercise, Step 5,
3-pressure HRSG with Reheat in Ts-diagram
T < 540 °C
X ~0.9
Challenge: Heat in fluegas after superheater not sufficient to

reach desired reheat temperature
Exercise, Step 6,
Splitting the superheater and reheater
Splitting the superheater and reheater allows higher reheat steam

temperature (because superheater 2 takes less heat from fluegas)
A splitting of superheaters and reheaters into additional heaters is possible

Exercise, Step 6,
Splitting of Heaters in Ts-Diagram
T = 540 °C
The desired reheat temperature (540 °C) can be rreached.

When mixing steam into cold reheat and before LP-turbine, there are significant
temperature differences (-> exergy loss)
Exercise, Step 7,
Superheat of IP and LP steam
By superheating IP and LP steam, exergy losses are reduced

when mixing the steam
Exercise, Step 7,
Superheat of IP/LP steam in Ts-Diagram
When mixing streams with similar temperature, the exergy losses are reduced

3-pressure HRSG in QT-Diagram
Significant difference in the „slope“ dT/dQ

between fluegas side and water/steam side
(because of high fluegas mass flow)
But temperature differences

(pinchpoints) are relatively small
(compared to coal fired boilers)

Comparison to coal-fired boiler:
coal fired boiler in QT-Diagram
In coal fired boilers (at same thermal power)

significantly lower fluegas flow (because fluegas
temperature is much higher)
Higher exergy losses in boiler because

of larger temperature differences in heat
transfer
Pinchpoint
(at „cold end“)

Comparison:
1-pressure HRSG in QT-diagram
In 1-pressure HRSG pinchpoint is located „in the middle“

-> large difference between feedwater ínlet temperature
and fluegas outlet temperature
The location of the pinchpoint (-> evaporation

pressure) determines the fluegas losses
Pinchpoint
(„in the middle“)
Therefore:
Evaporation at different pressure levels to High fluegas outlet
temperature and
reduce the fluegas outlet losses losss

Exercise, Step 8,
Water injections into SH and RH
Both controllers control the

injection massflows so, that
the target steam temperature
behind the heaters is
maintained (i.e. not exceeded)
The injections should be very small in the Design case (0.001 kg/s).
The controllers should be active only in Off-Design
Exercise, Step 9,
Auxiliary burner
In Off-design the controller sets

the fuel flow to the auxiliary
burner so, that the desired
steam temperature is reached
The auxiliary burner should be deactivated in Design case

The controllers should be active only in Off-design
Exercise, Step 10,
VTU GT-Lib for realistic GT data
Replace individual Ebsilon components of the GT with comp. 106,

Select a proper gas turbine (for example Siemens SGT5-3000E)
Exercise, Step 10,
VTU GT-Lib for a particular gas turbine
Calculates realistic results using manufacturers data
New Gasturbine Data

Meanwhile (GT-Lib Version 5) more than 600 Turbines
from 13 manufacturers
(Alstom, Ansaldo, Capstone, Centrax, GE, Hitachi, Kawasaki,

MAN, Mitsubishi, OPRA, Rolls-Royce, Siemens, Solar Turbines)
if required by the customer, datasets for additional turbines can

be created

Exercise, Step 10,
Consistent
Reference Conditions

Exercise, Step 10,
The maximum loadcase for the auxiliary burner is encountered at low

ambient temperatures, because then the fluegas temperature is low
Correction curve for fluegas outlet temperature as function of ambient temperature for
Siemens „SGT5-3000E (41MAC) Oil“
Exercise, Step 10,
Also in Off-design there is a drop in fluegas temperature
Correction curve for fluegas outlet temperature as function of ambient temperature for
Siemens „SGT5-3000E (41MAC) Oil“
Exercise, Step 11,
Auxiliary burner and Design case
Because the fluegas massflow is increased (when operating the

auxiliary burner), it is recommended to use the case with maximum
firing of the auxiliary burner as the Design case for the HRSG :
• Define the case with maximum firing of auxiliary burner as the
Design case for the complete plant

Exercise, Step 11,
auxiliary firing in QT-diagram

Alternative heat-exchanger components
component 20, drum
Comp. 20 : drum, for the separate modelling of evaporator and

drum

comp. 61, heat-exchanger with exponents
This heat-exchanger can be uses as alternative to comp.26
The specification values are the same like in comp. 26 with the
following additional options :
When specifying the Alpha-values of fluegas and water/steam side,

the component allows to calculate the heat-transfer area A and the
heat transfer coefficient k
For the Alpha-values of fluegas and water/steam side plausible values

are recommended (-> Online help of comp.61)
The Off-Design performance is calculated like the following
• 1/k = 1/ αi+1/αa
• αi/ αiN = (M1/M1N)**EX12
• αa/αaN = (M3/M3N)**EX34 *(1.-0005*(T34-T34N))

comp. 62, Duplex-heatexchanger
Duplex-heatexchanger (as extension of comp.61) as combination

of 2 heat-exchangers

comp. 88 and 89, boiler heating surface
Instead of the aforementioned heat-exchanger components also the

so-called „boiler components“ comp.88 („Boiler: fluegas zone“) and
comp.89 („Boiler: bundle heating surface“) can be used.
These components allow to calculate the heat-transfer taking into

acount geometry and material data.
The heat transfer coefficients (Alpha values) are calculated from
geometry and material data according to VDI Wärmeatlas Mb4
(there is an English edition, the „VDI heat atlas“)
Also a heat-transfer by radiation between neighbouring heating

surfaces is taken into account by these components
Remark: only since Ebsilon Rel.11 Patch 4 correct calculation according to VDI
Wärmeatlas. Earlier there were some simplified calculations

EbsWizard
Assisted creation of complete model
The EbsWizard allows to create a model of a GT + HRSG + water/steam-cycle in

very short time (5 minutes)
(prerequiste: VTU GT-Lib)

EbsWizard
Assisted creation of complete model
Modifications of internal details of Macros is possible by editing the Macros

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Modelling of Combined Cycle

• Gas turbine process using individual components

Modelling of gasturbine with Ebsilon-components

Modelling of HRSG with components

The recommended procedure for configuration of components :

• Evaporator (with drum) :

October 2017 Modelling of Combined Cycle Power Plant with EBSILONProfessional 5

Alternative Procedure for configuration of components

• Evaporator (with drum) :

October 2017 Modelling of Combined Cycle Power Plant with EBSILONProfessional 6

- Splitting the turbine into HP and LP turbine

October 2017 Modelling of Combined Cycle Power Plant with EBSILONProfessional 7

- Splitting the turbine into HP-, IP- and LP-turbine

October 2017 Modelling of Combined Cycle Power Plant with EBSILONProfessional 8

Challenge: steam quality at LP turbine outlet too small

- Steam leaving HP turbine is heated again

Challenge: Heat in fluegas after superheater not sufficient to

Splitting the superheater and reheater allows higher reheat steam

October 2017 Modelling of Combined Cycle Power Plant with EBSILONProfessional 12

The desired reheat temperature (540 °C) can be rreached.

By superheating IP and LP steam, exergy losses are reduced

October 2017 Modelling of Combined Cycle Power Plant with EBSILONProfessional 15

Significant difference in the „slope“ dT/dQ

But temperature differences

October 2017 Modelling of Combined Cycle Power Plant with EBSILONProfessional 16

In coal fired boilers (at same thermal power)

Higher exergy losses in boiler because

October 2017 Modelling of Combined Cycle Power Plant with EBSILONProfessional 17

In 1-pressure HRSG pinchpoint is located „in the middle“

The location of the pinchpoint (-> evaporation

October 2017 Modelling of Combined Cycle Power Plant with EBSILONProfessional 18

Both controllers control the

In Off-design the controller sets

The auxiliary burner should be deactivated in Design case

Replace individual Ebsilon components of the GT with comp. 106,

Calculates realistic results using manufacturers data

New Gasturbine Data

(Alstom, Ansaldo, Capstone, Centrax, GE, Hitachi, Kawasaki,

if required by the customer, datasets for additional turbines can

October 2017 Modelling of Combined Cycle Power Plant with EBSILONProfessional 22

October 2017 Modelling of Combined Cycle Power Plant with EBSILONProfessional 23

The maximum loadcase for the auxiliary burner is encountered at low

Also in Off-design there is a drop in fluegas temperature

Because the fluegas massflow is increased (when operating the

October 2017 Modelling of Combined Cycle Power Plant with EBSILONProfessional 26

October 2017 Modelling of Combined Cycle Power Plant with EBSILONProfessional 27

Comp. 20 : drum, for the separate modelling of evaporator and

October 2017 Modelling of Combined Cycle Power Plant with EBSILONProfessional 28

This heat-exchanger can be uses as alternative to comp.26

When specifying the Alpha-values of fluegas and water/steam side,

For the Alpha-values of fluegas and water/steam side plausible values

The Off-Design performance is calculated like the following

October 2017 Modelling of Combined Cycle Power Plant with EBSILONProfessional 29

Duplex-heatexchanger (as extension of comp.61) as combination

October 2017 Modelling of Combined Cycle Power Plant with EBSILONProfessional 30

Instead of the aforementioned heat-exchanger components also the

These components allow to calculate the heat-transfer taking into

Also a heat-transfer by radiation between neighbouring heating

October 2017 Modelling of Combined Cycle Power Plant with EBSILONProfessional 31

The EbsWizard allows to create a model of a GT + HRSG + water/steam-cycle in

(prerequiste: VTU GT-Lib)

October 2017 Modelling of Combined Cycle Power Plant with EBSILONProfessional 32

Modifications of internal details of Macros is possible by editing the Macros