Professional Documents
Culture Documents
Degradation Effects On Combined Cycle Power Plant Performance-Part III Gas and Steam Turbine Component Degradation Effects
Degradation Effects On Combined Cycle Power Plant Performance-Part III Gas and Steam Turbine Component Degradation Effects
306 Õ Vol. 126, APRIL 2004 Copyright © 2004 by ASME Transactions of the ASME
Journal of Engineering for Gas Turbines and Power APRIL 2004, Vol. 126 Õ 307
seems that the effect of either fouling or erosion is tending to have 8.3%兲 was at its highest value with superheater degradation by
a similar curvature trend, but the magnitude is different. 5%. Although the expectation was to see the highest change in
As this figure shows, the maximum degradation consequence mass flow variation with GT degradation, the results came up with
was encountered with gas turbine power deterioration due to GT different values. In reality, this increase in mass flow was not due
component erosion. This was around 共⫺15.2%兲 from the original to degraded superheater. In fact as Zwebek and Pilidis 关6兴 showed,
DP value. The corresponding plant thermal efficiency drop was the effect of degraded superheater alone on steam mass flow 共with
about 共⫺11.5%兲. out gas turbine degradation兲 is almost negligible 共⫹0.51%兲.
The combination of decreased compressor mass flow with an Therefore, as Eq. 共1兲 shows, the inlet conditions at the ST inlet are
increased turbine flow capacity, due to erosion by 5%, led to a controlled by the so-called nondimensional mass flow 共Eq. 共1兲
higher 共about 2.5%兲 reduction in the plant’s overall efficiency in above兲. Now by comparing the superheater degradation effects in
comparison to the case where both components are experiencing Figs. 4, 7, and 8 with GT degradation effects it will be observed
fouling. This is due to the fact that the decreased pressure ratio that while steam live pressure is almost constant 共Fig. 7兲, there
through the turbine due to erosion resulted in a lower power out- was an increase in steam mass flow. Now to fulfil the conditions
put of the turbine, and hence a reduced overall power output of of Eq. 共1兲, then the live steam temperature must increase. This is
the engine which then reflected on the engine’s overall efficiency. the result obtained 共as Fig. 8 shows兲. The same discussion is al-
This shows that the erosion effect of gas turbine gas path compo- most applicable to all other conditions.
nents on the gas turbine performance is higher than the fouling It is well known from the very basics of steam turbine cycle
effect. theory that the steam turbine power is a function of steam mass
flow and its enthalpy. Now by comparing Fig. 5 with Fig. 4 it
Steam Cycle Degradation Simulation Results would be observed that the steam turbine power is more or less
As it was explained above, since the trend of the GT degrada- following the mass flow behavior.
tion due to either fouling or erosion is the same, and they only The effects of degraded topping as well as bottoming cycle
differ in the magnitude, and due to the limited space 共page num- components on steam turbine power plant are illustrated in Fig. 5.
bers allowed for this paper兲 it was decided to discuss only the As this figure shows, the largest displacement of ST turbine power
fault which gave the higher impact on GT performance when from its original DP value was encountered with superheater as
simulating the bottoming cycle. Therefore, as already showed, well as condenser degradations. Again as stated above, this in-
since the GT erosion effects were predominant over the effect of crease in ST power is merely due to increased gas turbine exhaust
fouling, it was decided to use its values when simulating steam temperature due to GT degradation which led to increase steam
cycle performance degradation. mass flow and hence to increase the ST power. On the other hand,
The most important steam turbine cycle performance deteriora- the lowest effect on ST power resulted from GT degradation along
tion simulation results are represented graphically in Figs. 4 with ST turbine isentropic efficiency degradation; this was around
through 8. It is worth reminding the reader here that the values in ⫹4.2%.
these figures are including also the gas turbine degradation 共ero- One of the very important results obtained from this study is
sion兲 and GT exhaust back pressure rise effects due to HRSG that, unlike the case with GT or ST degradations alone where the
degradation as shown in Fig. 3. relationship between performance parameter variation 共ST power,
The GT degradation effects on ST as well as on CCGT plants ST Rankine, etc.兲 and deterioration is linear, in the case of both
was plotted within the graphs showing those plants degradation. plants deteriorated the relationship obtained was also nearly
Figure 4 shows the effects of degraded topping 共GT兲 as well as linear.
bottoming 共ST兲 cycles on the steam flow through the bottoming Cerri 关12兴 stated that the maximal CCGT efficiency is reached
cycle. As this figure shows, the increase in steam mass flow 共about when the GT exhaust temperature is higher than the one corre-
Journal of Engineering for Gas Turbines and Power APRIL 2004, Vol. 126 Õ 309
sponding to the maximum GT efficiency; i.e., as GT exhaust tem- dation, which is illustrated in Fig. 6. The thermal efficiency defi-
perature goes up, the CCGT efficiency goes up. Since gas turbine nition of steam turbine 共bottoming兲 plant is given by
efficiency is already at its maximum, and still by increasing GT
exhaust temperature 共due to any reason兲 the CCGT will increase. W SC
This would then implicitly indicate that this increase is gained by R⫽ . (2)
Q HRSG
increased steam turbine plant’s power due to the increased steam
turbine inlet conditions as explained above. This exactly coincides This equation shows that the steam turbine 共bottoming兲 cycle
with the results obtained in the current study 共see Fig. 5兲. efficiency is a function of steam turbine net power output and the
The next important performance parameter to discuss here is heat transferred in the HRSG (Q HRSG), which is representing the
the steam turbine plant 共Rankine兲 efficiency variation with degra- heat input to the steam cycle. Now by looking at Fig. 9 it will be
Fig. 5 Steam turbine power variation with gas and steam cycles component deg-
radation
seen that all types of degradations resulted into an increase in the well, nevertheless, the increase in Q HRSG was predominant and
HRSG efficiency, i.e., increased Q HRSG . As Fig. 5 shows, al- hence resulted in decreasing the ST turbine efficiency by approxi-
though ST power increased with all types of degradation as well, mately 3.3%.
yet the increase in the Q HRSG 共relative to DP value兲 in some cases As Figs. 5 and 6 show, the ST turbine isentropic efficiency has
was higher than the increase in ST power. This led to the ST a predominant effect over all other types of ST cycle degradations.
efficiency to fall with such cases. This can be clearly seen in the This is in agreement with the conclusion established by Zwebek
case of ST turbine isentropic degradation. In this case, the in- and Pilidis 关6兴.
crease in ST power was around 4.2% with 5% degradation. Al- The degradation effects of gas and steam plants on live steam
though 共as Fig. 9 shows兲 there was an increase in HRSG effi- pressure and temperature are expressed on Figs. 7 and 8, respec-
ciency by about 4.2% 共for the same magnitude of degradation兲 as tively. As Fig. 7 shows, the blockage of the steam turbine inlet due
Fig. 7 Live steam pressure variation with gas and steam cycles component deg-
radation
Journal of Engineering for Gas Turbines and Power APRIL 2004, Vol. 126 Õ 311
to fouling by 5.0% resulted in about 11.6% increase in live steam components degradation was to increase the GT exhaust tempera-
pressure at the ST turbine inlet. The combination of all other types ture. This, then by itself, led the live steam temperature to increase
of degradation with steam turbine fouling reduced the inlet pres- 共see explanation above兲.
sure to about 11.0%. On the other hand, the degradation of all
components along with steam turbine erosion by 5.0% resulted in
only 0.3% 共approximately兲 reduction in live steam pressure. Combined Cycle Degradation Results
In the case of live steam temperature, as Fig. 8 shows, the effect The degradation results have been explained in part by address-
of different components degradation on live steam temperature is ing the two cycles separately. Figure 10 shows the whole CCGT
mostly controlled by increased gas turbine exhaust temperature. plant’s power and how it varies with GT and ST plants
As already shown above 共see Fig. 3兲 the effect of gas turbine degradation.
Fig. 9 HRSG efficiency variation with gas Steam cycles component degradation
As this figure shows, although there was an increase in ST dation effect was due to the ST turbine isentropic efficiency deg-
power 共see Fig. 5兲, the decrease that was caused by GT power 共see radation along with GT degradation. This was about ⫺10.7% and
Fig. 3兲 was predominant. This actually is a straightforward result ⫺4.3% deterioration in CCGT power and efficiency respectively
since GT power counts for the two thirds of the total amount of with ⫺5.0% degradation.
CCGT power. Figure 11 is a reproduction of Fig. 9 showing the Figures 9 and 12 illustrate the degradation effects of both plants
CCGT efficiency is actually following the behavior of CCGT
on HRSG efficiency ( HRSG) and stack temperature, respectively.
power.
As the two previous figures showed, the GT turbine degradation The stack temperature is mainly a measure of the amount of gas
alone was having the least effect on CCGT plant power and effi- turbine exhaust heat utilization by the bottoming cycle. Also, by
ciency. On the other hand, when the ST component effects were definition, HRSG efficiency is a function of stack temperature and
included in the degradation, the outcome deterioration results HRSG exhaust inlet temperature for a given ambient temperature
started to increase. As these two figures show, the largest degra- 共Eq. 共3兲兲
Fig. 11 CCGT efficiency variation with gas steam cycles component degradation
Journal of Engineering for Gas Turbines and Power APRIL 2004, Vol. 126 Õ 313
Journal of Engineering for Gas Turbines and Power APRIL 2004, Vol. 126 Õ 315