89-GT10

THE AMERICAN SOCIETY OF MECHANICAL ENGINEERS

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Copyright © 1989 by ASME

Turbo-S.T.I. G.—The Turbocharged Steam Injected Gas

Turbine Cycle
R. W. FOSTER-PEGG
Independent Consultant
Cape May, New Jersey

BACKGROUND

Steam and water injection into gas

turbines has been practiced as long as there
ABSTRACT have been gas turbines. The first gas turbine
capable of self sustained operation
In this Steam Injected Gas turbine (Armengaud and Lemale in 1906) used extensive
cycle, maximum steam is raised with exhaust water injection (1).
heat at the highest practical pressure for Water injection has been used for power
expansion in a back pressure steam turbine augmentation in aircraft jet and turboprop
before injection into the gas turbine engines from about 1950. Steam injection has
combustor. Additional steam is raised at been used to augment power in industrial gas
lower pressure and injected into the turbines since about 1960 .
combustor, to effect more complete recovery In 1965 Stephens et al published a paper
of heat. The back pressure steam turbine on a system designed by Westinghouse (2).
drives a topping air compressor which raises Since that date, papers discussing steam
the gas cycle pressure ratio. This allows the injection have issued frequently. Cheng, who
standard gas turbine blading to accommodate has invented six patents relating to steam
the additional steam flow because of the injection into gas turbines, cites patents as
higher pressure and density of the gas. early as 1949 (3).
The efficiency and benefits of steam
NOMENCLATURE injection for power augmentation of gas
turbines have increased as technology and
STIG Steam Injected Gas turbine firing temperatures have advanced and led to
ISTIG Intercooled STIG greater use of the concept.
Turbo-STIG Turbo Steam Injected Gas turbine International Power Technology has sold
Expander Component in which gas (or steam) cycles covered by patents issued to Cheng.
expands to produce power The Evendale division of GE is selling the
EPRI Electric Power Research Institute steam injected LM 5000 (4), and promoting an
JCF'&L Jersey Central Power and Light advanced intercooled version, the ISTIG. EPRI
PG&E Pacific Gas and Electric and PG&E are rumored to have participated to
GE General Electric the extent of over one million dollars in
studies of STIG and ISTIG with GE presumably
CONVERSIONS TO SI contributing at least an equal amount. The
Gas Research Institute has funded studies of
Pascals = 6895 * psi steam injection systems and is now
Centigrade = (F-32) * 1.8 subsidizing an installation of an Allison 501
Joules = 1056 * Btu at a General Motors plant. Several other
Kg = .45=6 * Lb organizations are investigating the concept.
mm = 25.4 * inches Technical papers about steam injected
gas turbines proliferate at gas turbine and
power generation conferences.

Presented at the Gas Turbine and Aeroengine Congress and Exposition—June 4-8, 1989—Toronto, Ontario, Canada

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 STIGs-STEAM INJECTED GAS TURBINES
Steam may be injected to suppress air
pollutants arising from combustion of fuel or
to augment the gas turbine power output. A
STIG is any gas turbine into which steam is
injected primarily for power augmentation and
is the subject of this paper.
Steam is normally injected after the
compressor, is heated in the combustor along
with the air, and is expanded through the
expander. All the power produced by the
expansion of the steam is useful, compared to
one-third to one-half of the power produced
by expansion of air which must be compressed.
Injected steam thus has a dramatic effect on
the power output of the gas turbine. Injected
steam equal to one percent of airflow can
increase power by about four percent.
Without supplementary firing, the heat
recovery boiler of a STIG will raise steam
equal to 15 to 20% of the airflow of its gas
turbine by weight. A normal heavy gas turbine
can accept one third to one half that
quantity of injection steam but with some
loss of surge margin and flexibility.
To increase power instantaneously in the
event of an aborted landing, aircraft engines
have wider surge margins to allow large step
increases in firing temperature. When adapted
to stationary applications, smaller surge
margins are adequate. Thus aircraft engines
are able to accommodate greater proportions
of injected steam while maintaining adequate
surge margin for stationary applications.
This accounts for the successful use of steam
injection with the Allison 501 and the
General Electric LM 2500 and 5000. With these
engines, the quantity of steam that is
injected into the combustors is limited to
about 7'l. of airflow. In the LM 5000
additional steam is injected after the high
expander.
The steam injected into a gas turbine
increases the power of the expanders without
increasing the power absorbed by the
compressors. For best results, the increased
expander power should be transmitted directly
to the power output shaft. This requires a
single shaft gas turbine. If steam is
injected into a multi-shaft gas turbine, the
match of power and speed of the compressors
and expanders is changed. This may limit the
quantity and pressure of steam which can be
injected into the combustor and may require
some of the steam to be injected at lower
pressure. These limitations of multi-shaft
gas turbines result in less than optimum
efficiency and consideration of the Turbo-
STIG concept thus has been confined to single
shaft gas turbines.
The injection into the combustor of all
the steam which can be produced by recovered
heat results in the highest efficiency of
power generation. The injection of additional
steam produced by supplementary firing
reduces efficiency.
Steam raised at a pressure above the gas
turbine combustor pressure and expanded in a
steam turbine before injection into the
combustor produces an increment of power at
essentially 100% efficiency. With the higher
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main steam pressure, optimum heat recovery
and best cycle efficiency require that
additional steam be raised at a lower
pressure and directly injected into the
combustor.
The use of the steam turbine to drive a
topping air compressor to increase the
pressure ratio of the gas turbine further
increases efficiency. This is the Turbo-STIG
system.
The Turbo-STIG Cycle
The following description can be
followed more easily by using the diagram of
a Turbo-STIG, figure 1.
The gas turbine exhausts into an unfired
heat recovery boiler in which steam is raised
for injection into the gas turbine. A portion
of the steam can be exported for cogeneration
applications.
Maximum steam is raised at the highest
practical pressure and expanded in a back
pressure steam turbine before injection into
the gas turbine combustor. The back pressure
steam turbine drives an additional topping
air compressor which raises the gas cycle
pressure ratio to the higher pressure
required to pass the additional flow.
Additional steam is raised at lower pressure
to recover more exhaust heat and this steam
is injected directly into the combustor.
The configuration of the gas turbine is
that of a recuperated machine with the
recuperator replaced in the cycle by the
steam driven topping compressor.
For when all HP steam is being exported
or during startup without a supply of steam a
non return valve is provided to allow air to
pass by the topping compressor. If steam is
available the gas turbine can be started by
applying steam to the steam turbine to drive
the topping compressor. This will create a
flow of air through the machine, crank the
gas turbine and allow the combustor to be
lit. A mechanical cranking system can thus be
omitted and some cost saved.
The power from expansion of the steam is
sufficient to drive a topping compressor with
a pressure ratio of about 1.2. The air volume
flow through the topping compressor is small
relative to the inlet flow of the main
compressor and a small diameter one or two
stage axial or a centrifugal high speed
compressor would be suitable. Direct
connection of the topping compressor to the
steam turbine in a configuration somewhat
like a diesel turbocharger is most
appropriate.
A Turbo-STIG with standard compressor
and expander aerodynamics can accommodate all
the steam raised by heat recovered from its
exhaust without decrease of surge margin. Any
required modifications will be less extensive
than are required for previously proposed
full injection STIG cycles. The Turbo STIG
system improves the cycle efficiency relative
to normal STIGs, by increasing the overall
pressure ratio (of both steam and gas), by
steam reheat and by better matching of
components when some or all the steam is
exported and not injected. The low capital
cost common to all STIG systems is retained.
 950 F 63.74

80 F 67.B LIS

6eOF( 1.32 R

AMBIENT 14.7 P 00 F 60% RH 173P

215 P 520 F 4
1.42 LI695 F

9.18 US

960 P 540 F 138383 KW

240 P 398 F1 52475 KW
84191 KW
12 17 R
14.5 R

-4 W
15 W
400.14 LIS III 559 1046 F B0 F 325.8 Ll
F
271 F III^1 461
P - Pound per square inch absolute.
F - Degree Fahrenheit.
L = Pound Mass.
S = Second.
R = Pressure Ratio.
W = Inches Water Gage.
?2.6 LIS RH= Relative Humidity

FIG. 1 TURBO-STIG BASED ON CANADIAN WESTINGHOUSE 251 B10

F = Pound per square inch absolute.

F = Degree Fahrenheit.
110 F L = Pound Mass.

FIG. 2 LM 5000 STIG WITH WATER RECOVERY

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 The HP steam for injection into a
turbocharged STIG is raised at a pressure in
the range of three to ten times the gas
turbine combustor pressure. After expansion
in the back pressure steam turbine, the steam
mixes with the air compressed in the topping
compressor. Then both steam and air flow into
the gas turbine combustor where the air and
steam are raised to the expander inlet
temperature by combustion of fuel. For
optimum efficiency additional L.P.steam is
also injected into the combustor.
Modifications required to a gas turbine
to adapt it to a turbocharged system
include: injection ports for the steam:
changes to prevent reversal of cooling air
because the pressure at the inlet to the
expander exceeds the pressure at the outlet
of the main compressor: strengthening of
couplings and shafts because of increased
torques: adjustment of the thrust balance and
strengthening of casings because of the
approximately two atmospheres higher
pressure: incorporation of ports for
extraction and return of the compressed air.
A recuperated gas turbine will not require
the last modification.
Because of the higher power of STIG,
more powerful reduction gear and electric
generator will be required than the
equivalent machine without steam injection.
The power of a gas turbine is increased
approximately 100% by Turbo -STIG conversion.
As most power of an expander goes to drive
the compressor, which is not increased, the
power of the expander is increased by only
33-50%. The major stress in expander blading
arises from centrifugal force which is not
increased by conversion and the increase
applies only to the blade bending stress
which is normally 1/3 of the total blade
stress. Turbo -STIG conversion increases
expander blade stress by only about 15%.
The increased pressure at the inlet to
the expander of the STIG passes the increased
flow at the normal velocity. At the exhaust
of the expander, the pressure is not
increased and velocities will be raised with
the standard design. This will increase
leaving losses.
To minimize additional losses it is
prudent to select engines for STIG
applications which have generous exhaust
area. Failing this, a modification to
increase the back end area for a Turbo STIG
is less serious than opening up the expander
all the way through as required for a normal
STIG. The flow path of an expander can be
increased at minor cost by changing the angle
at which the nozzles and blades are inserted.
The flow areas of uncooled rows can
additionally be increased by cropping the
trailing edges of nozzles and blades.
If high exhaust flow is a problem, it
may be limited in the Turbo-STIG by closure
of the variable compressor inlet guide vanes
or stators thus restricting the airflow of
the engine. Power is reduced by this
procedure but efficiency is affected little.
The full air flow can then be restored by
reopening the compressor vanes or stators if
full steam injection is not required or in
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hot weather when flow is naturally reduced.
This works for the Turbo-STIG but not for non
turbo STIG because the reduced guide vane
setting reduces surge pressure ratio as well
as flow.
Commercially successful gas turbines are
without exception multiple products. The cost
of design and tooling for sophisticated
machinery is so high that the cost of "one
off" production or other than simple
modifications to a standard design is
prohibitive. Modification of static
components for STIG applications may be
acceptable but changes to blade path and
rotating components must be minor to be
affordable. This is accomplished by Turbo-
STIG . Other STIG systems require extensive
end-to-end modification of either the
compressor or the expander for all the steam
produced by recovered heat to be
accommodated.
Cogeneration
With the turbo system, steam can be
exported for cogeneration at the pressure
prevailing before, or after, the steam
turbine. Steam which is exported does not
increase the flow through the expander and
does not increase its inlet pressure.
Steam extracted after the steam turbine
will have produced power in the steam turbine
which drives the topping compressor. However
the flow through the gas turbine expander is
not increased by the steam which is
extracted. In this case, the pressure rise in
the topping compressor resulting from the
extracted steam reduces the pressure rise and
the power absorbed by the main compressor.
The power not required by the main compressor
then becomes output and improves overall
efficiency.
If required the boiler can be fired so
the extraction of steam for cogeneration does
not reduce the injected steam.
Water consumption of a STIG cycle
Higher firing temperatures, which
produce more NOx, and more stringent air
pollution regulations, have required water or
steam injection into most gas turbines for
NOx control. Thus most gas turbines now
require a demineralization system for the
injected water or steam which for NOx control
is about 27. of airflow. Steam injection for
power augmentation does not require a
demineralization plant to be added-only
enlarged. The water flow must be increased
from about 2% of airflow to 7-1S/. of airflow.
The water in the exhaust of a STIG can
be recovered by cooling the exhaust gas below
the dew point to condense the moisture and
capture the resulting liquid water drops in
chevron water separators. Many "condensing"
economizers are in commercial service on gas
fired boilers. A cycle diagram for a "Dry" LM
5000 STIG as conceived in the study reported
in reference 8) is shown on figure 2. The
exhaust of a STIG is substantially cooled in
its heat recovery boiler. For full water
recovery it must be further cooled to about
100 F by heat rejection to an extraneous heat
sink such as ambient air or water unsuitable
for injection.
 U

TABLE I COMPARISON OF NORMAL AND TURBO -STIG GAS TURBINE PERFORMANCE

GAS TURBINE MODEL CW 251 8 10 ABB TYPE 8 SULZER 3 3 ALLISON 501 SOLAR CENTAUR

CYCLE NORMAL TURBO NORMAL TURBO NORMAL TURBO SIMPLE TURBO SIMPLE TURBO
STIG STIG STIG STIG STIG

FUEL TYPE GAS GAS No2 No2 GAS GAS GAS GAS GAS GAS

AMBIENT F 80 80 60 60 60 60 60 60 60 60

AIR FLOW Lb/Sec 326 326 390 386 69.77 69.77 32.98 32.98 38.58 38.58

HP STEAM PSIG --- 900 --- 985 --- 800 --- 730 --- 800

HP STEAM F --- 950 --- 900 --- 850 --- 800 --- 900

STEAM INJ Lb/Sec --- 65 --- 68 --- 11.12 --- 6.43 --- 5.52

MAIN COMP RATIO 13.75 12.17 15.5 15.5 9.54 9.54 9.65 10.09 10.2 9.98

TOP COMP RATIO --- 1.32 --- 1.22 --- 1.25 --- 1.26 --- 1.19

EXPANDER RATIO 12.31 14.51 13.9 16.97 9.16 10.85 9.26 11.77 9.43 11.1

EXPANDER INLET F 2168 2168 1985 1985 1778 1778 1800 1850 1754 1754

FUEL 10a Btu/hr HHV 487.8 697.8 528 690 80.54 111.5 42.3 59.8 52.63 64.92

FUEL 10 a Btu/hr LHV 439.0 628.0 498.0 651.0 72.5 100.4 38.07 53.8 47.37 58.43

EXPANDER KW 94759 138-183 122063 163787 16573 22530 8055 11730 9412 12381

MAIN COMP KW 56196 52474 73426 72673 10184 10184 4713 4921 5783 5706

TOP COMP KW ---- 9336 ---- 8700 --- 1629 --- 803 --- 780

USEFUL POWER KW 37406 83349 47664 89000 6280 11967 32275 6673 3763 6475

HHV Btu/KWH 12216 8371 11079 77-,0 12825 9316 12916 8961 13987 10027

EFFICIENCY LHV 7. 31.00 45.30 32.77 46.66 29.57 40.71 29.36 42.32 27.11 77.82

The stack gas may be reheated to impart
buoyancy, after the water has been recovered,
by some of the heat extracted upstream to
cool and condense the moisture. The moisture
in the atmosphere and the combustion of
hydrocarbon fuel contribute water to the
exhaust such that only about 707. of the water
in the exhaust needs to be recovered to
satisfy the injection requirement.
Recovery of water to produce a dry plant
reduces STIG performance only marginally by
additional exhaust pressure drop and
auxiliary power. "Dry" plants with condensing
steam turbines suffer considerable
degradation of performance because of the
higher condenser pressure and auxiliary
power. Due to the lesser penalty for STIG
water recovery than to air cooled condensing
of a steam plant, a STIG may be the most
efficient "Dry" plant. Water recovery from a
STIG is discussed in reference 8.
PERFORMANCE
The heat rates of combined cycles
without supplementary firing and Turbo -STIG
systems with similar sophistication are
almost identical. Power of the Turbo-STIG
can be twice the power of the basic gas
turbine without steam injection. Power of an
un-refired combined cycle is typically
one-and-a-half times the dry gas turbine
power. Thus power of the Turbo-STIG is about
=37 greater than an unfired combined cycle
with the same gas turbine. The efficiency of
a combined cycle supplementary-fired to equal
the power of the Turbo -STIG is lower than the
STIG efficiency.
The efficiency of the Turbo STIG could
be equalled without the Turbo feature by a
Combined STIG with dual steam pressure. The
combined STIG with single steam pressure was
discussed in an EPRI study ( ,6), but without
dual steam pressure its efficiency would not
equal the Turbo -STIG. The Turbo and the
combined STIGs are more efficient than the
other STIG cycles because of the higher steam
expansion ratio and the reheat of the steam.
As a Turbo -STIG the expander produces
33-50r more power than normal; the main
compressor power is about the same as in the
normal engine; and net power can be increased
by about 100'1..
Fuel demand is increased by 40% to heat
the injected steam from the steam turbine
outlet temperature of about 60OF and the
slightly hotter than normal compressed air,
to combustor outlet temperature.
Basic gas turbines need the following
modifications to convert them to the Turbo-
STIG cycle.
1. A system to extract the compressed air
rather than sending the air directly to the
combustor.

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 2. Provision of an inlet to the combustor
for the same air after further compression in Sulzer Type = . This engine is available
the topping compressor and for the injected in regenerative configuration and is single
steam. shaft. It would be relatively easy to
3. Strengthening the combustor and expander reconfigure as a Turbo STIG.
casings for the higher pressure.
4. Strengthening the shafts and couplings, Allison 501 KH is available with steam
including a larger drive end bearing. injection ports as a normal STIG and several
are in service in this form. The 501 is a
5. Adjustment of the thrust balance and
cooling air. single shaft engine and is well suited for
6. Replacing the reduction gear and configuration as a Turbo STIG.
electric generator with higher rated units. The Allison 501 would make an excellent
7. The addition of the topping compressor demonstration of the Turbo STIG concept. The
and its steam turbine. resulting installation would be commercially
B. The addition of the heat recovery boiler viable.
and associated equipment.
Table I lists the performance predicted The Solar Centaur is a single shaft
at sea level and 60/. relative humidity for engine available in regenerative
several single shaft gas turbines when configuration. Solar manufactures heat
converted to Turbo-STIG. recovery boilers and pipeline gas compressors
suitable for the topping compressor and is
For each engine the normal performance
developing small steam turbines suitable for
is listed first, followed by the performance
driving the topping compressor.
calculated for the Turbo -STIG modified
The Solar Centaur is a natural choice
engine.
for a Turbo STIG which would both have
The normal performance of the engines is
commercial applications and demonstrate the
obtained from specifications published in
concept.
reference 7, except for the CW 251 which is
The performance of the Turbo -STIG
from manufacturers" data. A calculation is
Centaur is calculated with a single steam
made first to duplicate the basic
pressure for simplicity. The performance
performance. The performance of the engine in
would be better with two pressures.
the Turbo-STIG configuration is then
calculated using component efficiencies,
ECONOMIC (AND OTHER) COMPARISONS
pressure losses, etc. found to duplicate the
basic performance. If the operating
A STIG power plant produces power from a
conditions of the components are
fuel like other power plants, and to be
significantly more arduous in the Turbo -STIG
preferred, must offer advantages over an
than normal operation, the values may be
ordinary combined cycle. EFRI and JCP?L
changed to reflect additional losses.
compared normal STIG (not Turbo-STIG) with
The Turbo -STIG cycle for all the engines
combined cycles in a study summarized in
is similar to the CW 251 which is depicted on
reference 8.
figure 1, unless stated otherwise.
The study concluded that commercially
The efficiencies of the topping
available STIG plants are economically
compressor and of its driving steam turbine
inferior to combined cycles.
are assumed in the range of 70-80 7, depending
The STIGs were found to be less
on size.
efficient and except for the smallest
An additional 27 pressure loss is
capacity, more costly. Consequently the power
assumed for the entry and exhaust ducts of
production cost of the STIGs was higher than
the topping compressor.
for the combined cycles which gave the STIGs
the inferior rating.
Comments on the engines listed in Tabl e I.
For the STIG plants the study considered
Canadian Westinghouse 251 E+10 . Figure 1. the only gas turbine of a utility size
shows this engine in Turbo -STIG form.No
presently available as a STIG. The features
regenerative version of the CW251 has been
of STIG found to be unfavorable are largely
built but the 251 is derived from the CW191
due to the characteristics of this, otherwise
and has spawned the CW352. Both the 191 and
excellent, gas turbine when used in STIG
the 352 are made as regenerative engines, so
configuration.
no difficulties are expected in converting
The reasons are reviewed below.
the 251 design for compressed air export and
Alternative conclusions should a Turbo -STIG
import.
become available are also drawn.
The power increase by the Turbo -STIG
Although the disadvantages of the STIGs
modification of the CW 251 is greater than
predominated, some advantages were found, as
for the other engines because of higher
follows:
firing temperature.

Asea Brown Boveri Type 8. BE<C engines

all have single external combustors, which
simplify modification for export and import
of the compressed air.

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P

For the cost estimate the gas turbine

will be regarded as separated into packages
Advantages of STIG consisting of electric generator, gear, and
1. A STIG plant requiring multiple gas
shafting assumed to cost 25% of the total and
turbines is completely modular. The multiple
the remainder 757. of the total.
gas turbines of a large STIG plant can all
The Turbo-STIG conversion is assumed to
operate separately at full efficiency and as
increase the power by 90% requiring higher
soon as they are installed. In a combined
capacity electric generator, gear, and
cycle, the multiple gas turbines are
shafting to accommodate the 45 MW power
connected to a single steam turbine and can
increase. This package will be changed for
operate at full efficiency only when the
one of higher capacity for which the added
plant is all complete. The full modularity of
cost is the incremental cost. The added cost
STIG also gives better part load operation.
will be 25'/. of 150 $/kw on 45,000 kw or
2. The large injection of steam results in
$1,688,000.
lower NOx emissions. Plumes from the stack
The combustor and expander casings will
and cooling tower of STIG were found to be
need to be strengthened to accommodate the
less intrusive than from the combined cycles.
207 higher pressure and the interconnecting
3. Total water consumption for cooling
ducting is an addition. The steam turbine and
tower and steam injection (for NOx control in
topping compressor can be used as a starting
the combined cycles) is less for STIG than
device and the normal cranking device
for combined cycle.
omitted, a reduction. To cover these items
4. The STIG is faster starting from cold.
the cost of the remainder of the engine is
assumed to increase by 10% of 75% of $10
Disadvantages of STIG. million = $750,000
1. The normal STIG plants studied are
The power of the topping compressor and
significantly less efficient (107..) than the
its steam turbine will be about 207. of the
comparable capacity combined cycles.
original gas turbine rating or 10 MW. At $125
2. In capacities above 50 MW the STIG
per kw for this simple two bearing machine
plants had higher capital costs.
the cost is $1,250,000.
3. The operation and maintenance cost of
The added cost of the STIG conversion of
the STIGs (other than fuel)is marginally
the gas turbine on this basis is $3,687,000
higher than for the combined cycles.
for a total cost of the 95 MW Turbo-STIG
4. The surge margins of STIG gas turbines
engine of $13.687 million or $144/kw.
will be less than normal and may cause
The cost of the balance of the complete
operational problems. (Authors conclusion,
Turbo-STIG plant is estimated as follows:
not a conclusion of the reference 8 study ).
Water usage is about 3 Lb per Kwh. Thus,
for 95 MW, 285 MLb/Hr of demineralized water
Turbo -STIG Evaluation will be needed.
The impact of the replacement of the
In the study (8) the cost of
studied STIG by a Turbo-STIG will now be
purification, pumping and a heat recovery
addressed. The disadvantages of the STIG
boiler to supply 285 M Lb/Hr of demineralized
found in the study will first be reassessed
steam to a STIG was estimated to be $11.26
for a Turbo-STIG.
million or $118.5/kw of the 95 MW plant.
Structural and electrical categories of
1. Efficiency. A Turbo-STIG is as efficient a STIG plant not included in the above costs
as combined cycles with similar levels of
were estimated at $185/kw (8).
technology. Thus this disadvantage of an
By the writer's estimate the total
ordinary STIG would be eliminated in the case
direct costs of the 95 MW Turbo-STIG plant
of a Turbo-STIG.
are approximately $448/kw as listed in Table
2. Capital Cost. To address the issue of II.
capital cost, one must determine the probable
cost of a Turbo-STIG gas turbine and of the TABLE II.TURBO-STIG COST ESTIMATE
complete Turbo-STIG power plant.
Basic 50 MW Gas Turbine Generator $M 10,000
Since no gas turbine manufacturer has
Larger Generator, Gear, Shafts 1,688
offered an estimate of the cost of a
Strengthen Casings, etc. 750.
Turbo-STIG engine, the author submits his
Topping Compressor & Turbine 1,250
own.
Total 95 MW Turbo-STIG Engine 13,687
The Cost Estimate of a Turbo-STIG 11,260
Steam Supply. 285 MLb/hr.
commences with a hypothetical heavy gas 17,575
Structural, Electrical, etc.
turbine generator with an ISO rating of 50 MW 42,522
Total 95 MW Power Plant $M
which is assumed to be redesigned and 447.6
Total 95 MW Power Plant $/kw
constructed as a Turbo-STIG. Reference 7
gives $10 million as a typical cost for a 50
The study (8) placed the cost of a 95 MW
MW heavy gas turbine ($200/kw). A typical
similar basis combined cycle at $550/kw. By
cost for a 100 MW unit is $17.5 million
this estimate the cost of a Turbo-STIG power
($175/kw). The incremental cost from 50 to
plant should be lower cost than a comparable
100 MW is thus $7.5 million (150/kw).
combined cycle thus eliminating STIG
disadvantage #2.

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 C

3. Cost of Maintenance. The cost of

maintaining a STIG (Other than Fuel) was
found to be marginally higher than for a
comparable combined cycle. The difference is
not significant and would be reduced by the ACKNOWLEDGEMENTS
lower specific cost of the Turbo-STIG which
would lead to lower specific cost of The Data in table I have been discussed
replacement parts and labor. with all of the listed engine manufacturers.
The manufacturers have neither disagreed
4.Surge Margin. The topping compressor of the with, nor endorsed, the performance
Turbo-STIG eliminates this problem. calculated for their turbines in the Turbo-
STIG configuration.
Conclusions of the Revised Comparison
The Turbo-STIG cycle potentially could LIST OF REFERENCES.
eliminate all the disadvantages of ordinary
STIGs found in the EPRI-JCP&L study (8). 1. Anon, Brown-Boveri Review, June 1939.
One advantage of Turbo-STIG not yet
mentioned is the more simple system compared 2. Stephens,J.O., Boho,M.J., Young,W.E.,
to a combined cycle. Items in a combined More Kilowatts for Less Dollars.
cycle not required in a STIG include the ASME 65-PWR-5.
major portion of a steam turbine, condenser,
cooling tower, boiler bypass stack and 3. Cheng,Dah Yu, Parallel-Compound Dual-
starting cranking device. The Turbo-STIG Fluid Heat Engine,
in-stead requires a small steam turbine and a U.S. Patent 3,978,661, Sept 7 1976.
topping compressor. The STIG demineralizer
and steam injection system are larger than in 4. Soroka,G, Kamali,K, Modular Remotely
a combined cycle, but they are needed by both Operated, Fully Steam-Injected Plant for
plants. It is an axiom that reliability is an Utility Application. ASME Joint Power
inverse exponential function of the number of Generation Conference 1987.
components in a system. The fewer components
in a Turbo-STIG plant compared to a combined 5. Brown, D.H., Steam Injected Gas Turbine
cycle will be reflected in higher Study: An Economic and Thermodynamic
reliability. Appraisal.
E.P.R.I. T.P.S. 77-737, September 1979.

SUMMARY AND CONCLUSIONS 6. Brown, D.H., Cohn, A., An Evaluation of

Steam Injected Gas Turbine Systems.
The turbocharged STIG accepts all the ASME-80-GT-51.
steam raised by heat recovery without losing
surge margin and without major modifications 7. Gas Turbine World Handbook 1987,
of the standard gas turbine. Pequot Publishing.
The Turbo is superior to other
fully-injected STIG systems because: 8. Laar,J.A., Wendorf,A.W., Cohn,A.,
1) it requires less engine modification Esposito, N.T., Foster-Pegg,R.W.,
2) inherent matching to the quantity of Site Assessment of STIG and Combined
injected steam from full to zero. Cycle Plants. ASME 88-JPGC-PWR-21.
The lower capital cost of the Turbo-STIG and
its equal heat rate relative to its combined
cycle competitor would result in a lower cost
of power from the Turbo-STIG.
Other advantages of STIGs relative to
combined cycles identified in reference 8
apply equally to the Turbo-STIG, suggesting
that in circumstances of normal water
availability Turbo-STIG power plants would be
superior to combined cycles on many counts .
The water consumption of the Turbo-STIG
can be reduced significantly with minor cost
and performance penalties. This ability may
make the Turbo-STIG the preferred power plant
for base load in arid areas, by a wide
margin.
If this writers predictions are
substantiated, the Turbo-STIG may be
preferred for all gas or distillate oil fired
mid and base load power plants.

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