Combined Cycle Systems For The Utility Industry

Combined Cycle Systems For the Utility Industry
TABLE OF CONTENTS
Introduction 3
Basic Power Plant 4

Conventional Steam Power Plants 4
Simple Cycle Peaking Plants 5
Combined Cycle Power Plant s 5
Gas Turbines Basics 7

History 7
Applications of Gas Turbines 9
Brayton Cycle 10
Performance Characteristics 11
Heat Recovery Steam Generator 12
Steam Turbine 12
Generators 13
Controls 13
Ancillary Equipment 14
Plant Operation 15
Plant Arrangement 15
Installation 15
Future Load Expansion 15
Author’s Experience 16
Background 16
Diverter Damper Description 18
Conclusions 22
References 23
INTRODUCTION:
Power plants can be defined by functional type (e.g. base load, peak load, or combined
cycle). Each has advantages and disadvantages.
Base load power plants have the lowest operating cost and generate power most in any
given year. There are several different types of base load power plants. The resources
available typically determine the type of base load plant used to generate power. Coal
and nuclear power plants are the primary types of base load power plants used in the
Mid-West United States.
There are four types of base load power plants:
o High efficient combined cycle plants fueled by natural gas

o Nuclear Power Plants
o Conventional steam power plants fueled primarily by coal
o Hydropower plants
Peak load power plants are simple cycle gas turbines that have the highest operating cost
but are the cheapest to build. They are operated infrequently and are used to meet peak
electricity demands in period of high use and are primarily fueled with natural gas or oil.
The high efficient combined cycle power plant will be the focus of this project.
Gas turbines have increased in capacity over the last 25 to 45 years. Gas Turbines with
rated outputs of 40 to over 350 MW that have increased specific power has led to the
parallel development of highly efficient economical combined cycle power generation
systems.
Each combine cycle (CCGT) power-generating system consists of a gas turbine, Heat
Recovery Steam Generators (HRSGs), generators, controls, and a steam turbine.
Combined cycle systems typically are an optimized system of high technology power
generating equipment, software, and services that are integrated into the utilities ancillary
equipment to create an economical and stable power generating facility.
Combined cycle systems encompass a large range of capabilities for both 50 and 60 Hz
operation. Combined cycle systems are versatile allowing for many different
configurations to satisfy the requirements of individual applications.
There are two major categories of combined cycle systems:
1 Oil or natural gas fired systems for power generation.
2 Combined cycle cogeneration systems and coal or oil fired integrated

gasification combined cycle (IGGG) power generation systems.
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There are many configurations for combined cycle systems. A significant portion of the
systems contain an electrically controlled diverter damper, seal air fans, position
indicators, and some type of control systems that integrates these components. It is the
intent of this project to describe one such system that the author helped design, install,
verify, and commission. The duration of the project, located in the Mid Atlantic region
of the United States, was over 24 months in duration. The construction phase was in two
parts. The first phase consisted of installation of three 100 MW rated turbines, ancillary
equipment and commissioning of simple cycle operation while the HRSGs were being
completed. This was completed in a relatively short period of approximately twelve
months. The commissioning of the combined cycle systems is happening as this paper is
being prepared (May 2002).
BASIC POWER PLANTS:
There are many types of power generating power plants. The basic features of the three
most common types are described below. The steam plant, the simple cycle peaking
units and the combined cycle power plants basic features are described below. After the
basic features are described, much time will be spent on the combined cycle plant and the
components that make up such a power generation facility.
Conventional Steam Power plants:
The conventional power plant that has been the basis for electric power generation for
many years burns fuel to heat a boiler to produce steam. The steam is then used to turn a
steam turbine that drives an electric generator. The steam is then condensed back to water
(this requires the use of cooling water) and then is reheated. Conventional steam power
plants can use a variety of fuels, basically anything that burns can be used. Typical fuels
are coal, gas, oil, or biomass.
Features of conventional steam power plants are:
They are about 34% efficient in converting fuel to electricity.
Their heat rate is about 10,000 Btu (British Thermal Units) of fuel “heat”
burned per kilowatt-hour (kWh).
Conventional steam power plants are slow to start or to change output while
operating.
The low operating cost of steam power plants is a result of the inexpensive fuel
used.
With coal costs of $1.35/MMBtu, the fuel cost of producing electricity is

about 1.35 cents/kWh New.
Simple Cycle Peaking Units:

Simple-cycle power generation plants are simply the basic gas turbine mounted in a noise
reducing enclosure. Typically they are aeroderivative type gas turbines similar to jet
aircraft engines. As a comparison, an engine of a Boeing 737 is equivalent to a 25 to 30
MW simple cycle power plant.
Simple cycle power plants typically use natural gas as fuel with kerosene or distillate oil
as a back up. They are used to meet the highest (peak) electricity demands, for example
very hot summer afternoons.
Basic features of a simple cycle power plant are listed below:
Simple cycle power plants have a heat rate of 9,900 to 12,000 Btu/kWh (28 to
35% efficient).
The start up time to full load is approximately 10- 20 minutes.
Low operation and maintenance (O & M) costs. This is because they have few
moving parts or staff requirements and the moving parts move in a radial motion
vs. the piston type motion of other internal combustion engines.
They are expensive to operate. The high fuel cost (relative to base load power
plants) makes for expensive peak power.
Assuming natural gas costs of $3.50 MMBtu, the fuel cost of producing
electricity is 4 cents/kWh New.
Combined Cycle Power Plant:
A combined cycle gas turbine power plant is essentially an electrical power plant in
which a gas turbine and a steam turbine are used in combination to achieve greater
efficiency than would be possible independently. The gas turbine drives an electrical
generator while the gas turbine exhaust is used to produce steam in a heat exchanger
(called a Heat Recovery Steam Generator, HRSG) to supply a steam turbine whose
output provides the means to generate more electricity. If the steam is used for heat (e.g.
heating buildings) then the plant would be referred to as a cogeneration plant
Figure 1 is simple representation of a CCGT system. It demonstrates the fact that a

CCGT system is two heat engines in series. The upper engine is the gas turbine. The gas
turbine exhaust is the input to the lower engine (a steam turbine). The steam turbine
exhausts heat via a steam condenser to the atmosphere.

Figure 1: Schematic of Combined Cycle (CCGT) power plant. Overall efficiency
(ηCC) is a combination of the efficiency of the Brayton (ηB) gas turbine cycle and the
Rankine steam turbine cycle (ηR). Total combined cycle efficiency is ηCC =ηB + ηR –
(ηB * ηR) Chase.
The combine cycle efficiency (ηCC) can be derived by the equation 1 Langston.
ηCC = ηB + ηR - (ηB * ηR) (1)
Equation (1) states that the sum of the individual efficiencies minus the product of the
individual efficiencies equals the combine cycle efficiency. This simple equation gives
significant insight to why combine cycle systems are successful.
For example, suppose the gas turbines efficiency ηB is 40% (a reasonable value for a
toady’s gas turbines) and that the steam turbine efficiency ηR is 30% (a reasonable value
for Rankine Cycle steam turbine).
Utilizing equation (1) would lead to the following conclusion.
ηCC = 0.4 + 0.3 – (0.4 * 0.3)

ηCC = 0.58

ηCC = 58%
The combined cycle efficiency of 58% is much greater than either the gas turbine or the
steam turbines efficiencies separately. The 58% value is slightly misleading in that
system losses were ignored. Efficiency values in the 60% range have been recorded for
CCGT systems in the past few years Chase.
CCGT power plants may come in many different configurations. Some companies choose
to treat the gas turbine exhaust bypass stack as a commodity, others choose to incorporate
a diverter damper into the turbine exhaust gas path. The diverter damper allows for the
rapid configuration of the power plant as a combined cycle or simple cycle system. The
initial cost of the diverter damper is much higher than the cost of treating the gas turbine
exhaust stack as a commodity however, the diverter damper allows for the gas turbines to
be operated in simple cycle when HRSG or steam turbine repair or maintenance is
required.
Some of the basic features of the combine cycle power plant are listed below:
Combined cycle plants use the hot exhaust gas from gas turbines to make steam,
which drives a steam turbine which drives a generator to produce electricity.
Power output of the steam turbine is typically 1/3 of the total output of the total
power output of the combine cycle power plant. It is this “extra” electricity
produced from the same amount of turbine energy (without additional fuel
consumption) that makes a combined cycle plant much more efficient than a
simple cycle gas turbine peaking plant.
Overall efficiency of converting fuel to electricity is greater than a peaking plant

44 to 52% (Heat Rate of 6,600 to 7,700 BTU/kWh).
The steam portion of combined cycle plants takes approximately 1.5 to 3 hours to
heat up. This is much slower than a true peaking plant that can be at load in about
10 – 20 minutes.
The combine cycle system cost is obviously a more expensive capital expenditure
than a peaking plant (simple cycle plant).
However, a combine cycle plant has a high efficiency in converting fuel to

electricity which makes it possible for relatively high price fuels like natural gas
to be competitive for intermediate or base loads.
For natural gas costing $3.50/MMBtu, the fuel costs of producing

electricity is about 2.3 cents/kWH, which is less, expensive than some coal
fired plants NEW.

Described below are the features of major components of a CCGT power generating
plant that are required for safe efficient reliable combined-cycle systems.
GAS TURBINE BASICS:
History:
A turbine is any kind of spinning device that uses the action of a fluid to produce work.
Air, wind, water, steam, and helium are typical fluids used by a turbine to produce work.
Windmills and hydroelectric dams have used turbine action for decades to turn the core
of an electrical generator to produce power for residential and industrial applications.
Simpler turbines are much older with the first known appearance dating to the time of
ancient Greece Langston.
Gas Turbines are relatively new in the history of energy conversion. The first practical
gas turbine used to generate electricity ran at Neuchatel, Switzerland in 1939, and was
developed by the Brown Boveri Company. The first gas turbine powered airplane flight
also took place in 1939 in Germany, using the gas turbine developed by Hans P. von
Ohain Langston.
The simultaneous development of the gas turbine for electric power generation field and
the aviation field led to the gas turbine being known by several different names. The
electric utility industry generally refers to the gas turbine as a gas turbine, combustion
turbine, a turboshaft engine, and sometimes a gas turbine engine. The aviation industry
generally to the gas turbine as a jet engine. Various other names will be used depending
on the application or engine configuration such as jet turbine engine, turbojet, turbofan,
fan-jet, and turboprop or propjet (when used to drive a propeller).
Many people assume that gas turbines use gas as its fuel. However, a gas turbine uses a
compressor to suck in and compress gas (usually air), a combustor to add fuel to heat the
compressed air, and a turbine to extract power from the hot air flow. Gas Turbines are
internal combustion (IC) engines that implement a continuous combustion process. An
intermittent combustion process characterizes IC engines used in automotive or diesel
applications.
Figure 2 is the schematic of the two basic types of Gas Turbines. The schematic
represented by (a) is the aircraft engine and the schematic (b) represents a land-based gas
turbine typically used for power generation in the utility industry. The compressor,
combustor, and turbine part of figure 2 is commonly called the gas generator Langston.

Figure 2: Schematic for (a) an aircraft jet engine and (b) for a land based gas
turbine Langston.
Applications of Gas Turbines:
The aircraft gas turbine output is used to turn the compressor (which may have an
associated fan or propeller). The hot air flow of the turbine is then accelerated through an
exhaust nozzle into the atmosphere to provide thrust (propulsion power). Aircraft engines
output can range from about 100 pounds of thrust to as high as 100,000 pounds of thrust
and range in weight from 30 pounds to 20,000 pounds.
In non-aviation gas turbines, part of the turbine power is used to drive the compressor.
The remainder, the ‘useful power’ is used as an output shaft power to turn an energy
conversion device (figure 2b) such as an electrical generator or a ship’s propeller.
Land based gas turbines range in power output from 0.05MW (Megawatts) to greater
than 550 MW. The lighter weight units derived from aircraft jet engines are know as
basic aeroderivative type engines. Aeroderivative engines traditionally are utilized to
drive compressors at natural gas pipelines pumping stations, power ships, and to provide
peaking power for electric utility applications. Peaking power supplements a utility’s
normal power output during high demand periods (summer demand on hot days).
However, they are increasing being used for base load electrical generation and combine
cycle operation Langston. Larger heavier weight machines designed for land applications
serving the utility industry are called industrial or frame engines.
The gas turbine machine has five principal advantages listed below:

1 The gas turbine produces a large amount of useful power in a relatively small size
and weight.
2 Maintenance cost is relatively low and its mechanical life is long when compared
to a piston driven engine. All the gas turbine major components that move do so
in rotation (no reciprocating motion as in a piston engine). However, repair costs
are typically much higher for a gas turbine than for a reciprocating engine.
3 The start up time for a gas turbine to full load is measured in minutes vs. hours for
a steam turbine plant.
4 Gas Turbines can operate utilizing a wide variety of fuels. Natural gas is typically
used for land based machines while a lighter distillate is used for aircraft
applications.
5 Atmospheric air is typically the working fluid for gas turbines and generally
requires no coolant for basic power generation Langston.
Low efficiency (high fuel usage) was a major disadvantage of gas turbines in the past
when compared to other IC engines and steam turbine power plants. Continuous
engineering development work over the past fifty years has pushed the thermal efficiency
for 18% in 1939 to about 43 % today for simple cycle operation and 60 % for combined
cycle operation Chase. These thermal efficiency values are significantly higher than for
other prime providers of electrical power such as steam power plants.
The Brayton Cycle:
Gas turbine cycles describe what happens to air as it passes into, through, and out of the
gas turbine. The cycle describes the relationship between the volume (V) of air in the
system and the pressure (P) the air is under. The Brayton cycle developed in 1876,
shown in graphic form as Figure 3 is a pressure-volume diagram that represents the
properties of a fixed amount of air passing through a gas turbine in operation. Figure 4
shows the same Brayton cycle point on an engine schematic.

Figure 3: Brayton Cycle pressure-volume diagram for a unit mass of working fluid
(e.g. air), showing work (W) and heat (Q) inputs and outputs Langston.
Air is compressed from point 1 to point 2 increasing the gas pressure as the volume of the
space containing the air is reduced. The air, at constant pressure, is heated from point 2
to point 3. This is accomplished by injecting fuel into the combustor and continuously
igniting the fuel. Expanding air from point 3 to point 4 reduces the gas pressure and
temperature and increases the volume of the gas. In the engine schematic of figure 4, this
represents the flow through the turbine to point 3’ and then flow from the power turbine
to point 4 to turn a shaft. The useful work in figure 3 is indicated by the curve from point
3’ to point 4. The useful work is the energy available to cause output shaft power for a
land based gas turbine (used to turn a generator for the utility energy). Exhausting the
gas turbine exhaust gas to atmosphere where the volume of air cools resulting in less
volume completes the Brayton cycle. Heat from the exhaust gas is absorbed into the
atmosphere Langston.
Figure 4: Gas Turbine schematic showing relative points

of the Brayton Cycle Langston.
Performance Characteristics:
Specific power is the key performance characteristics of a gas turbine engine that
influences combined-cycle performance. Specific power is the power produced by the gas
turbine per unit of airflow (kW output per lb/sec of compressor airflow). High specific
power provides the lowest simple-cycle cost while ensuring the highest combined-cycle
operation efficiency.
Combined-cycle thermal efficiency increases as gas turbine specific power increases. The
gas turbine firing temperature is the primary determinant of specific power.
Development of high temperature/high strength materials, corrosion resistant coatings,
and improved cooling technology have led to increases in gas turbine firing temperatures.
This increase in firing temperature is the primary development that has led to increases in
CCGT thermal efficiencies. The improvements in combined-cycle thermal efficiencies
and the commercial development of combined-cycle power plants have proceeded in
parallel with advances in gas turbine technologies Chase.
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Typical gas turbine exhaust gas temperatures of 1000-11000F are well suited to efficient
combine-cycle operation. The exhaust gas temperature enables the heat transfer from
exhaust gas to steam cycle to occur with minimal temperature difference. This small
difference ensures maximum in thermodynamic availability while operating with the
highest steam cycle efficiency.
Gas turbine materials, coatings, and cooling systems enable reliable high firing
temperatures. This achieves high gas turbine specific power and high efficiency of
combined-cycle operation.
HEAT RECOVERY STEAM GENERATOR:
HRSGs are typically unfired and modular in design with finned-tube heat transfer
surfaces and natural or forced-circulation evaporators. Figure 5 is an illustration of a
Natural-circulation HRSG with modular construction.
Figure 5: Natural Circulation HRSG modular construction Chase.
Combined-cycle power plants typically have many common features and several unique
features that are site specific. A common arrangement is to have each gas turbine exhaust
to a single HRSG. There are systems designed that two gas turbines would exhaust into a
single HRSG. All HRSGs would exhaust into a common header that feeds the steam
turbine. HRSG design features are:
Flexible tube support system to enable fast startup and load following capability.
Low gas side pressure drop for optimum gas turbine performance.
Large modular factory tested modules that can be shipped to provide reduce
installation time and competitive construction cost Chase.
STEAM TURBINE:
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Steam turbines for combined-cycle power plants generally are of two styles. Steam
turbines with different exhaust annulus areas are available to permit optimization to meet
specific condenser cooling conditions. Steam turbines with large annulus areas are more
expensive, but provide increased capability and may be the most economical selection for
applications with low steam turbine exhaust pressures. Steam turbines with small
exhaust annulus area provide comparable or higher capability and low cost and are the
more economical choice when steam turbine exhaust pressures are high.
Combined cycle steam turbines have features that include but are not limited to:
Modules assembled where they can be shipped and field assembled with a low
profile installation, reducing installation time and cost.
Borescopic inspection access ports where the upper turbine casing does not have
to be removed during inspection.
Main cold and hot reheat pipes as well as the main steam pipes connect to the
lower half of the shell. This allows removal of the upper half shell for
maintenance.
GENERATORS:
Air cooled generators are standard for small combined cycle systems utilizing gas
turbines rated at approximately 100 MW and below. They may be open ventilated or
completely enclosed water-to-air cooled. Hydrogen-cooled generators are standard for
larger systems. Hydrogen cooled generators can be cooled by plant-cooling water or by
ambient air with water-to air heat exchangers Chase.
CONTROLS:
Combined-cycle power plants typically have a distributed digital control (DCS) with
redundant data transmission paths. Station operator controls provide an interactive color
graphic displays of the overall combine-cycle system to enable the operator to operate the
plant.
While the control systems for each installation may be tailored to the particular plant,
they will all have the same principal objectives of simple operation, easy starting,
automated operation and excellent load following capability. Each of the main
components of the combine-cycle system will have individual control panels and
interfaces that relay information to and from the plant operator through data ports to the
operator console. Operator consoles generally have a detailed graphic display with a high
level of detail that enables convenient and informative interaction with the plant as
required.
Most control systems operate with a minimum of control loops. This in conjunction with
well-established, automated operation of system components allows effective automation
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of the complete power plant. This minimizes the number of control operators. Most
systems operate with only one control operator and one roving operator.
Typical multi-shaft control systems are configured to enable automated startup and
operation after remote manual starting of plant auxiliaries, remote manual operation of
each major component, or operation of the gas turbine-generator units from local-control
compartments. Maximum availability is ensured because the plant can be operated
remotely with no additional control room operators. Equipment protection is typically
provided within the control unit thereby ensuring that normal protection is maintained
during all modes of operation, including local or remote manual operation.
Typical single shaft control systems are microprocessor-based controllers that coordinate
the operation of each of the components in each integrated combined-cycle unit and
communicate with the plant control. Because of the simple steam cycle, the tandem
coupling of the gas and steam turbines to a single generator, and the elimination of the
HRSG exhaust-gas, bypass system, the single-shaft control system is simple. Starting,
operation, and shutdown of individual components are automatic. Single-shaft units
typically controlled by a local control unit that is coupled to the central control operator’s
console by a data port. One control room operator and a one local operator can operate
one or more single shaft combine cycle units Chase.
ANCILLARY EQUIPMENT:
The combined-cycle system can be equipped with several types of ancillary equipment.
One such piece of ancillary equipment is a diverter damper. A diverter damper is a
device that directs the gas turbine exhaust flow to either the HRSG for combine-cycle
operation or to a bypass stack for simple cycle operation. The installation of a new
combined cycle power plant is a major operation that is measured in months if not years.
Typically, the utility will chose to complete the project in phases where phase 1 is to
install the turbine(s) in simple cycle mode with the appropriate ancillary equipment
(which may or may not include a diverter damper). This allows the utility to sell the
power generated by the gas turbines much sooner than if the entire project had to be
completed to sell power. Phase 2 usually entails bringing the HRSG(s) and the steam
turbine online.
Some utilities choose to treat the gas turbine exhaust bypass stack as a commodity, others
choose to incorporate a diverter damper into the turbine exhaust gas path. The diverter
damper allows for the rapid configuration of the power plant as a combined cycle or
simple cycle system. The initial cost of the diverter damper is much higher than the cost
of treating the gas turbine exhaust stack as a commodity however, the diverter damper
allows for the gas turbines to be operated in simple cycle when HRSG or steam turbine
repair or maintenance is required.
Two basic types of diverter dampers are generally used for combine-cycle power plant
operation. Electrical driven actuators are used for smaller gas turbines (upper limit of
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approximately 110 MW). Larger gas turbines with the higher exhaust rates generally
require hydraulic actuators to provide enough force to open and close the damper.
Diverter dampers require an electrical control system, control logic, safety switches, local
and remote operation capability, limit switches, and a seal air system that is an integral
part of the main control system. Such a system is described in more detail in the
following pages. Photos of an actual site and the control diagram and wiring schematics
are included for completeness.
PLANT OPERATION:
Gas turbines are constant volume mass flow dependent engines. Gas turbines exhaust
flow and temperatures vary with ambient temperature and barometric pressure. As the
ambient temperature decrease the gas turbine will experience a low heat-rate and increase
in power output. Steam production and steam turbine output vary with the gas turbines
exhaust gas flow and temperature supplied to the HRSG. The steam turbine should be
sized so that their rated flow matches the steam production.
PLANT ARRANGEMENT:
Combine-cycle equipment can be and should be adapted to installation requirements

defined by varying climatic conditions, system configurations and owner/operator
preferences. Combine-cycle equipment is suitable for outdoor installations, semi-outdoor
installations, or fully enclosed installations.
INSTALLATION:
Short installation time and low installation costs of combined cycle systems are key
features contributing to economical power generation. Factory packaging of major
components and containerized shipment of small parts is a major factor in keeping
installation cost down. Short installation time helps reduce the amount of interest
payments during the construction phase.
The time from order to commercial operation for standard combine cycle systems
typically range from 20 to 30 months excluding permits. The gas turbines typically
produce 60 to 70 % to the power plants capacity. Typically the gas turbines can be
installed in 12 to 18 months and be providing power while the steam system is being
completed.
FUTURE LOAD EXPANSION:
Economics of power generation can be improved by installation generation capacity as

the demand grows instead of having over capacity. Combine-cycle power plants allow
generation to be increase as the load demand grows. Efficient, low cost plants are
available in small modules of generating capacity.
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Future capacity can be added quickly by modifying existing simple cycle gas turbine
installations to combine-cycle operation when load demands require additional capacity.
Site plans for the steam turbine and transmission line capability are the main
considerations during the initial commitment for simple-cycle gas turbines.
AUTHOR’S EXPERIENCE:
The scope of a combine cycle power plant design and installation is such that there is
typically one prime contractor and many sub contractors who are responsible for some
sub system(s) of the power plant. Recently, I was the lead engineer and the program
manager for Universal Silencer’s scope of supply for a 550 MW combine cycle plant
installation in the Middle Atlantic region of the United States.
The scope of Universal Silencer, for whom I am employed, was the diverter damper and
its ancillary equipment. Ancillary equipment for the diverter damper includes seal air
fans, the AC drive motors for the damper and seal air fans, and the electronic controls for
the damper, seal air fans, emergency stops, position sensors, and the electrical interface to
the plants distributed control system (DCS). The turbine bypass exhaust stacks, the
acoustic silencer was also in Universal Silencers scope of supply.
The scope of supply for Universal Silencer was completed in the 1st stage of combine
cycle plant installation where the plant was operated in simple cycle however I, along
with two other engineers, returned to complete the installation once the HRSG and steam
turbine was installed. The following pages described some of the finer points of such an
installation and will focus on the diverter damper and the controls for such a system.
The use of the drawings included is with the permission of Universal Silencer and is
not to be reproduced without written permission of Universal Silencer.
Project Management
Combined Cycle System in the Middle Atlantic Region
Of
The United States
Background:
Universal Silencer received a purchase order from a Mid Atlantic power utility company
in February 2000 for the design, fabrication, and installation of a diverter damper and an
exhaust bypass stack for three 100 MW gas turbines used in a combine cycle power plant.
Universal Silencer fabricated the by-pass stack silencers and plenum and contracted out
the fabrication of the diverter damper and site installation services. Although the diverter
damper fabrication was subcontracted Universal Silencer maintained design control and
responsibility of all components within its scope including the electronic controls.
15

Combined Cycle Plant during installation
The photo above is meant to demonstrate the size of the plants. The tall stacks on the left
are the exhaust stacks for the steam generation portion of the combine cycle system. The
shorter lighter colored stacks on the right are the exhaust bypass stacks for the three 100
MW gas turbines. The stacks in the background are for the existing combine cycle
systems.
A second photo is included to indicate the time duration of these types of projects by the
changing system. The author experienced such seasonal changes as witness by being in
the foreground of the 2nd picture.
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Same Combine Cycle system at different stage of installation
The photo above again demonstrates the size of these systems. A bypass stack for one of
the three gas turbines can be seen in the background of the photo. The HRSG is located
in the cream colored building. The diverter damper is located in the base unit of the stack
and is also cream colored with vertical stiffeners. The turbine and the turbine enclosure
are to the far right of the diverter damper and not in the photo.
Diverter Damper Description:
The purpose of the diverter damper is to direct the gas turbine exhaust flow to the
atmosphere for simple cycle operation or to the HRSG for combine cycle plant operation.
Seal air systems are used to seal the diverter tight against the appropriate mating surface.
Electronic control of the diverter damper and seal air system must be integrated to
prevent exhaust gas leakage from the sealing surface.
The seal air system provides sealing air to the diverter damper whenever the damper is
either the full open or full closed position thus preventing exhaust gas from escaping
from the desired gas path. Radial type fans are used to provide the needed airflow and
control valves are used to direct the airflow to the desired mating surface. The control of
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the seal air system is such that the flow control valves automatically open or close as the
diverter damper passes the 30 and 600 positions directing the seal air flow to the required
sealing surface.
The control of the diverter damper, and the seal air system can be operated remotely from
the power plants control room or manually from a local control panel. Included in the
control panel are safety switches, power transformers, local control switches for the fan,
actuator, and valves.
In the past the electronic control for this system was simply to fully open or close the
damper. Recent developments in the industry have led to using the diverter damper as a
trottling device to bring the HRSG (and thereby the steam turbine) up to speed quicker
allowing the utility to achieve rated load quicker.
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Local Control Panel for the Diverter Damper and Seal Air System
For a Combined cycle System
The above photo is of the local control panel for the diverter damper. Please take note of
the safety tags as safety is always of major concern during any installation of this type.
While the box may seem simple at first glance it is a major sub component to the entire
power plant because the remote operation of the system is also routed through the control
box.
Figure 7: Three-Phase Power for the Diverter Damper Control System.

Printed with the permission of Universal Silencer and not to reproduced without
written approval of Universal Silencer
Figure 7 is the three phase power schematic for the diverter damper control system.
Three-phase 480 Vac power the control electronics. Power switch contacts prevent the
system from operation when the control panel door is open.
480 Vac power is then fed to the damper open and damper close contacts to position the
damper as appropriate for plant operation. 480 Vac power is supplied to the Limitorque
three- phase motor to move the diverter damper into the desired position.
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Operation of the seal air fan is automatically determined by the position of the diverter
damper and is driven by a 20 HP motor which requires 480 Vac three-phase power. It
was convenient to tap off the same power used for the diverter damper motor.
Separately, the 480 Vac three-phase power is routed to a 1.1KVA 480 Vac to 120 Vac
step down transformer to supply 115 Vac line voltage to the damper and seal air systems.
Figure 8: Electrical Control Schematic for the diverter damper. Printed with the
permission of Universal Silencer and not to reproduced without written approval of
Universal Silencer
Figure 8 is the electrical control schematic for the diverter damper and illustrates the
control mechanism for the diverter damper system and associated ancillary equipment.
L1 from Figure 7 is the high side of the line voltage just as L2 from Figure 7 is the
common side.
L1 is fed to the control circuits of Figure 8 through a master switch that selects between
local, remote, or secures the system. Control of the diverter damper system is through the
power plants control room when the master switch is in the remote position. Local
operation of the diverter damper system is allowed with the master switch in the local
position. The off position (with appropriate out tags in place) allow for maintenance and
troubleshooting of the diverter damper system.
The dotted line control path in the upper left-hand corner of figure 8 illustrates remote
control of the diverter damper from the DCS.
20

L1 refers to non-switched 115 Vac power routed directly from the step down transformer,
while L1-1 refers to 115 Vac switched at the master switch.
L1-1 is then routed to the damper open and close switches to allow local control of the
diverter damper. Additionally, L1-1 is routed to JOG seal-air switch, which controls the
seal air fan starter, L1-1 is also routed to the JOG bypass seal air valve, and the JOG
HRSG seal air valve switches that automatically control the corresponding valves routing
the seal air to the appropriate damper sealing system.
Non switched 115 Vac (L1) is routed to the main diverter damper actuator heating circuit
to prevent freezing of the circuits during winter months. L1 is also fed to the all indicator
lights to provide the roving plant operator an indication of system status. Additionally L1
is feed to the heating circuits of the bypass and HRSG seal air valve actuators. The
Limitorque actuators have position limiting circuits to prevent overdriving the diverter
damper. These circuits also require non-switched L1 power for proper operation.
CONCLUSION:
Combine Cycle systems are efficient low cost systems that provides assurances of
performance and operating objectives. Combine Cycle systems can be customized to the
utility needs and preferences. They offer attractive economical reliable power
generation. Operating flexibility of Combine Cycle power generating warrant their
consideration for most power generation applications.
Besides they are fun to work on and offer the utility engineer a unique and challenging
design opportunity.
Jim Causey
21

References:
Langston, Lee S. University of Colorado, Opdyke, George Jr., Dykewood Enterprises,

Introduction to Gas Turbines for Non Engineers
Chase D.L. and Kehoe P.T. GE Power Systems, Schenectady, NY: GE Combined-Cycle
Product Line and Performance.
New Power Plant primer. Energy and Environmental Analysis, Inc. and the Clean Air
Task Force in cooperation with the Mid-West Power Plant campaign. March 2001.
22

Combined Cycle Power Plant
The Combined Cycle Power Plant consists of two gas turbine -
generator units Siemens V 94.2, two heat recovery steam
generators, a steam turbine - generator complete with a condenser
and condensate / feedwater system and all required auxiliaries.
A gas turbine that drives its own generator, exhaust into a special
boiler called a Heat Recovery Steam Generator (HRSG) that
generates steam for use in Steam Turbine. One of the principal
reasons for the popularity of the combined cycle power plants is
their high thermal efficiency. Combined cycle plants with thermal
efficiencies as high as 52% have been built. Combined cycle plants
can achieve these high efficiencies because much of the heat
exhaust from the gas turbine(s) is captured and used in the Rankine
cycle portion of the plant. Refer figure. The heat from the exhaust
gases would normally be lost to the atmosphere in an open cycle gas
turbine.
Steam from auxiliary steam boiler
Steam Turbine Cycle
Left Rankine Cycle
Right
Gas Turbine Cycle
HP Stop Valve Right
HP Steam Control Valve
Brayton Cycle Steam

Condenser
Cooling
Condensate
Gland Steam Extraction
Condenser Pumps
Block-3: Combined Cycle Gas Turbine, Compressor, HRSG & Steam Turbine
Another reason for the popularity of combined cycle plant is that it

requires less time for their construction as compared to a
conventional steam power plant of the same output. Although it
takes longer time to build a combined cycle plant than a simple gas
turbine plant. Natural gas is the most common fuel used by
combined cycle gas turbine power plants. At KAPCO three fuels are
used i.e. Gas, HSD and Furnace Oil.
The main components of a Combined Cycle include the following:

 Gas Turbine  Diverter  HRSG
Damper
 Steam Turbine  Feedwater  Condenser and Condensate
2
Pumps Pumps
 Cooling Tower
etc
Introduction to GT V94.2 and ST

1.0MECHANICAL PLANT
The two gas turbines are provided to fire natural gas, high speed
diesel oil and furnace oil (heavy fuel oil).
The Siemens V94.2 gas turbines are driving the air cooled
generators, which have max. output power of 170 MVA (144 MW at
pf = 0.85). The gas turbines flue gasses are directly conveyed to the
2
adjacent heat recovery boilers the energy of which is transferred to
the feedwater loop.
The HP-system of the boiler is producing the HP steam. For this
purpose it has to be supplied with the right amount of feedwater at
any time during its operation: e.g. during start up, load variations
etc. Additional it has to produce steam of a specific quality, which
means of correct pressure and temperature which varies again with
the different operation modes and load conditions. The HP-system
generates steam at 60 bar / 530 °C from the thermal energy
contained in the GT exhaust gas.
The LP-system of the boiler is producing the LP-steam. For this
purpose it has to be supplied with the right amount of feedwater at
any time during its operation: e.g. during start up, load variations
etc. The LP-steam in the range of 3-10 bar is used for condensate
heating and for the feedwater deaeration in the deaerator.
The main steam flows to the steam turbine which drives the air
cooled generator of max. 175 MVA (150 MW at pf = 0.85). The steam
turbine is designed as a single - shaft machine with separate HP and
LP sections. The HP section is a single flow cylinder and the LP
section is a double flow cylinder. Turbine bypass system is to dump
the extra steam in the condenser during startup and steam
unloading conditions. Both the exhaust steam and the bypass steam
are condensed by means of a water cooled box type condenser.
Condensate pumps take suction from the condenser hot well and
discharge through the gland steam condenser and the LP-preheater
to the feedwater storage tank. One condensate storage tank for
controlling the water level is provided. The condensate is further
deaerated in the feedwater tank to the specified oxygen content. LP-
feedwater pumps feed the water from the storage tank to the drums
of the preheating system in the HRSG's in order to preheat the
feedwater in the feedwater storage tank. An auxiliary steam system
Prepared by: Fazal-ur-Rehman Babar Siemens Gas Turbines V 94.2

Cell: 92 322 6729767

3
supplies steam for the turbine gland sealing and for the feedwater
tank heating during start up.
HP-feedwater pumps deliver the feedwater into boiler drums of the
steam generators at the design pressure under all operating
conditions. The function of the circulating water system is to provide
a heat sink for the condenser and remove the heat to the
environment via the cooling tower. Further the system is connected
with the closed cooling water system via the service cooling water
system.
The task of the service cooling water system is to remove the heat
absorbed by the closed cooling water system in cooling components
of the gas turbine generator, the steam-, condensate- and feedwater
cycle via the closed cooling water heat exchanger and to transfer
this heat to the circulating water system.
A water treatment plant consists of a make-up water 3

demineralization plant, regeneration station with chemical storage
tanks and regeneration wastes neutralization is installed with all
necessary equipment for satisfactory operation of the CCPP.
Furthermore a chlorination plant for the main circulating water

system and for the fresh water (Muzafargarh Canal) system is
installed.
2.0ELECTRICAL SYSTEM
The figure 1.1 shows the electrical systems configuration of the CCPP in a
simplified manner. Each gas turbine generator unit and the steam turbine
generator unit are interconnected via its own main transformers to the
220 kV switchyard.
The gas turbine generator is capable of being fully automatically started

by electrical energy fed from the main grid via 220/11 kV main unit
transformer and the unit auxiliary transformer. The steam turbine
generator unit can be started via the 11 kV switchgears either from unit
13 or from unit 14 which are connected by means of bus-coupler to the 11
kV switchgear of the steam turbine generator.
The auxiliary power system is designed to meet all plant auxiliaries and
related buildings service requirements. Power for the auxiliary power
systems is fed from the unit auxiliary transformer via the 11 kV
switchgear. Low voltage auxiliary transformers supply the 380 V unit
switchgear as a 100% back-up. The second supply is interlocked from the
first, so that an operation without interruption shall be possible.

Cell: 92 322 6729767

4
The emergency diesel set has sufficient capacity for emergency supply of
the units, turning gears and emergency light. The capacity covered the
gas turbine units as well as the steam turbine unit.
The DC system consists of a 220V DC and ± 24V DC system. The 220V DC

system feed all power, control and protection equipment as required. The
± 24V DC system feed the I & C equipment and the protection equipment
as required. The capacity of each battery charger is 100% of the power
requirements of the whole plant extension. Each battery is designed to
allow for normal operation as well as for safe shut-down of the plant in
case of a total black-out.

Cell: 92 322 6729767

D14Q20
D13Q20
220 kV 220 kV
Feeder Feeder
220 KV Bus Bar-
New Multan 4 New Multan 3
2
GS GS
D13Q
011 011
2
GS GS
220KV Bus Bar-1
D13Q
011 D14Q GS 011 GS
D14Q
1
GS 2 010 GS 010
010 1 010
3
D14Q
GS GS
GS 012 GS 012
012 012 D13Q
3
021
GS
022
GS
021
GS
020
GS
022
GS
020
GS
Generator Generator
Isolator GS 033 Isolator GS 033
Portable Portable
earths earths
Main Unit Tr. Main Unit Tr.
11KV / 14BAT0 11KV / 13BAT0
220KV 1 220KV 1
Transformer
Transformer
14BBT0
13BBT0
Unit Aux.
Unit Aux.
14BAC01GS002 13BAC01GS002
1
1
11KV Isolator 11KV Isolator
14BAC01GS001 13BBT0 13BAC01GS001 5

11KV Breaker 14BBT0 11KV Breaker
1GT002
1GT002 14BBE 11KV 11KV 13BBE
GS001
1
13BFT0
GT001
14MBJ01
13BFT0
GT001
1
14MKC0
00GS00
13MKC0
13MBJ0
GS001
COBCB
GT001
GT001
Spare
1
1
Transformer
Excitation
Transformer
LV Unit Aux
00BHT 02
00BHT 04
00BHT 03
00BHT 01
00BLT 01
00BLT 01
Transformer
Transformer
00BMT
00BMT 00BMF
Frequency
Frequency
01
01
Transformer
13BFT 01
Start
Start
13MBJ 01
LV Unit Aux
14BFT 01
14MBJ 01
Transformer
13MKC
14MKC
Excitation
01
01
COBCB
00BHA
00BMF
00BHA
To
380V 00BLE
G 380V 00BHP G
Turbine Compress GT-14 GT-13
or
14BFE 13BFE
380V 380V
00BME 380V
Prepared by: Fazal-ur-Rehman Babar

EDG
behind CCR-3
6
3.0 CONTROL SYSTEM

The CCPP plant features a high level of automation with plant start
up, operation and shut down being carried out by the TELEPERM ME
control and data acquisition system. For the control system the total
plant is divided into following five functional areas:
1. Gas Turbines
2. Heat Recovery Boilers
3. Water/Steam Cycles
4. Steam Turbine
5. Auxiliary Plant
The I & C equipment associated with these functional areas is
distributed throughout the plant and transmit the measured values
and plant status information to local processing units contained
within Power Control Centers. These PCC's are prefabricated units
and enclosed in containers where also the plant related switchgear
is arranged.
The Central Control is located in the Control Room Building 15 UCA
(CCR-3). Information transfer between the control room and the local
plant is achieved via a duplicated data highway. Central redundant
data acquisition and control processors are located in the control
room building for alarm monitoring, logging and plant status display.
The interface between plant and operator is located in the both
central and local control rooms. From here, all plant control functions
can be carried out during both normal and emergency situations.
At Block-3, for the process automation of the CCPP, the TELEPERM ME
process I & C system is used. Its functions are: acquisition and
processing of process data, open and closed-loop control, calculation
and optimizing as well as supervision, signaling, operation and
monitoring of the process in interactive mode on the screen and
using miniaturized control room equipment.
4.0 Start-up from Unit Coordination Program

The plant can be operated in a simple-cycle and a combined-cycle
operation.
Simple-Cycle Operation
The procedure for startup of the gas turbine in simple-cycle operation is
as follows:
- Diverter damper upstream of the steam generator closed, bypass
path open
- Starting of gas turbine, purging of the turbine through bypass stack
during runup to ignition speed
- Ignition of the gas turbine burners
- Runup to rated speed and loading of the gas turbine
Combined-Cycle Operation
Prepared by: Fazal-ur-Rehman Babar GT 13, 14 & ST 15

7
Two procedures are possible for startup of the heat recovery steam
generator (HRSG):
- Startup of the gas turbine as a function of output load control
- Startup of the gas turbine as a function of exhaust temperature
control
The gas turbine is started up as described in the simple-cycle
operation, however, the gas turbine exhaust gas temperature is kept
below < 350 °C. After the purging process (for 1 min), gas turbine
output is increased to rated power. The rated temperature is
achieved at about 60% gas turbine output. Startup of the HRSG is
performed by opening the diverter damper upstream of the steam
generator and thus simultaneously closing the bypass path.
In the case of gas turbine startup under temperature control,
the bypass path remains closed after the steam generator has been
purged. The gas turbine load is controlled at the permissible
temperature transients for the thick-walled components of the steam
generator, piping and steam turbine.
For gas turbine startup under load control, the diverter damper is set
at an intermediate position after the steam generator has been purged
such that the cross-section of the line to the steam generator is opened
by about 20%. After expulsion of the water and when the level in the
drums stabilizes and the steam temperature is almost equal to the gas
turbine exhaust gas temperature, the diverter is opened in stages.
Whenever a temperature change in the HRSG permits, a defined time
pulse is released to open the diverter damper a stage further.
The main steam line is warmed up, in accordance with a specified mean
warmup transient, for the leading item (strainer casing). Controlled
warmup of the LP-steam line to the feedwater tank is not necessary owing
to the reduced wall thickness.
The steam turbine is started up under speed control. As soon as the
generator is synchronized with the grid system, the valve lift, which
is limited by the Turbine Stress Evaluator (TSE), is increased by the
startup control until the turbine assumes the full steam mass flow,
the turbine bypass station closes and the initial pressure controller
is activated.
The pressure in the LP-evaporator system is governed by the LP-
startup station. If sufficient hot steam is extracted to the feedwater
tank, the LP-startup station closes and lowers the response setpoint.
5.0Plant Design According to Weather Conditions

The HRSG / Steam Turbine plant are capable of utilizing the exhaust
gas from the gas turbines when operating over full range of
operating conditions up to base load according to Kot Addu site
ambient temperatures from 1 °C to 50 °C (design temperature) and
at relative humidity of up to 80 % (design ambient relative humidity
for electrical and I & C equipment).

8
The machines are designed according to the following performance

data:
Ambient Temperature = 30°C,
Relative Humidity = 60 %
Atmospheric Pressure = 0.996 bar.
The electric output of Block-3 (GT-13, 14 & ST-15) is 406 MW (Net
Power Output = 397 MW), 129 MW from each gas turbine and 148
MW from the steam turbine. The heat input amounts to 818 MJ/sec
so that the overall net efficiency is 48.5 %.
Combined Cycle Components
Some of the components are described here;
1.0 The Gas Turbine

The first major component of the combined cycle power plant is the gas
turbine. Gas Turbine is a machine which runs with the action of flue
gases on its turbine blades. Flue gases are produced by burning the fuel.
When gas turbine exhausts directly to the atmosphere, it is said to be
operating in "open cycle" mode. When a gas turbine exhausts into a heat
recovery steam generator (HRSG) the resultant steam is used to operate
a steam turbine, this operation is called “combined cycle”.
A model of gas turbine 13, 14 is shown. Unit 13, 14 gas turbines

consist of a single body including 16 stage Compressor, 2
Combustion Chambers and 4 stage Turbine. The turbine rotor has
two bearings one at the air inlet of compressor side and second in
the turbine exhaust. The body is divided in various planes to
facilitate inspection. Mechanical power generated in the turbine is
used to drive both the compressor and the generator. The electric
power is available at the generator terminals in 11KV.
The gas turbine uses air as working fluid which is drawn in through
filters and sound absorbers, it is compressed in the compressor up to
10 bar. Compressed air is directed into the combustion chambers.
Fuel is added and burnt in the combustion chamber, and the resultant
flue gas is heated up to approx. 1050 °C for the turbine inlet. The hot
gases are expanded to atmospheric pressure in the turbine and
transfer their energy to the turbine blades, where its energy is used
to drive the shaft. The compressor and turbine blades are arranged
on a common shaft and connected to the generator via the
intermediate shaft. The exhaust gases leave the turbine through the

9
exhaust diffuser for being discharged into the bypass stack or to the
HRSG for combined cycle operation.
1.1Main Components of a Gas Turbine

1.1.1Intake Air Filters
These provide clean, filtered and dust free air to the compressor
inlet.
1.1.2Compressor
Air is drawn in and compressed when passing through rows of
rotating blades and stationary vanes. At the end of the compressor,
before reaching the combustion chamber, the air is compressed to
about 10 bar and has been heated to about 300°C by compression.
1.1.3Combustor / Combustion Chamber
The combustor or combustion chamber is the heart of the engine;
here the combustible mixture of compressed air and fuel is burnt.
The hot gas output temperature becomes 1000°C to 1300°C; its
volume becomes more than doubled by the temperature rise where
as pressure remains constant.
1.1.4Turbine
The turbine section converts the thermal and kinetic energy of the
combustion gases into rotational mechanical energy. Gas turbines like
steam turbines have three or four stages of rotating and stationary
blades. However; because gas turbines work with lower initial inlet
pressures, they have fewer stages and less change in blade height from
inlet to exhaust. Turbines normally consist of combination of impulse and
reaction types. The gas turbine also differs from the steam turbine in;
(1) the type of blading material used
(2) the lower ratio of blade length to wheel diameter
(3) less number of turbine stages
Flue gases flow to the turbine with a very high velocity v of about 80
m/s (288 km/hr). It means it has high kinetic energy ½mv . The 2
kinetic energy of flue gases is converted to mechanical energy when

flue gas is expanded in the stages of turbine transferring its energy
to the turbine rotor. The volume of flue gases is increased by
expansion and thus temperature is decreased and at the exhaust it
is about 500 °C.
The turbine parts which are mechanically stressed are at the same
time subject to very high temperature, so that these parts are
designed with special material and cooling paths are provided for
cooling air to flow.
1.1.5Exhaust diffuser
It diverts the de-energized (but still hot) flue gases into the
ambience to complete the cycle. It is fitted with filter and silencer.
Prepared by: Fazal-ur-Rehman Babar GT 13, 14 & ST 15Prepared by: Fazl-ur-Rehman Babar

10
2.0 Heat Recovery Steam Generator (HRSG)

The HRSG is basically a heat exchanger composed of a series of
economizer, evaporator and superheater sections. These sections
are positioned from gas inlet to gas outlet to maximize heat
recovery from the gas turbine exhaust gases. The heat recovered in
the HRSG is used to supply steam to the steam turbine at the proper
temperature and pressure. The exhaust gases temperature leaving
turbines are in the range as given bellow:
Unit No. Exhaust temperature Steam flow rate
1& 2 500 °C to 550 °C 205 Tons/hour on Gas
220 Tons/hour on FO
3& 4 550 °C to 610 °C 210 Tons/hour
5–8 480 °C to 530 °C 150 Tons/hour on Gas
160 Tons/hour on FO
13 & 14 530 °C to 550 °C 203 Tons/hour on Gas
200 Tons/hour on FO
High temperature gas represents a source of heat energy, some of
which can be recovered thus the output and the efficiency of a
combined cycle power plant is increased.
The function of a heat recovery steam generator (HRSG) is to
recover the waste heat available in these exhaust gases and transfer
that waste heat to water and steam. The heat is used to generate
steam at high pressure and high temperature. The steam is then
used to generate additional power in a steam turbine driven
generator. The HRSG provides a link between the gas turbine and
the steam turbine in a combined cycle plant. Therefore, the HRSG is
a key component in combined cycle efficiency.
2.1 Main Components of an HRSG

2.1.1 Diverter Damper
At outlet of the gas turbine, upstream the boiler, a diverter is
provided which makes it possible to send the exhaust gas directly to
the atmosphere, by means of a bypass stack or to heat the boiler by
opening the path towards the HRSG. The diverter is provided with
hydraulic actuators. The actuators have been sized to permit
intermittent operation of the damper to a predetermined position,
but not regulated control. The ‘close position’ is with the blade
closed to HRSG and the open to bypass stack. The ‘open position’ is
with the blade open to HRSG and the close to bypass stack.
The diverter damper is actuated through the various modes of
operation by an electrically controlled hydraulic system. This
hydraulic system comprises an independent, self contained power
unit connected electrically and hydraulically to the diverter blade.
The power unit consists of a weather proof enclosure containing a
system of two motor pump units, one control valve assembly, a hand
pump system and 3 hydraulic accumulators.

11
2.1.2 Water & Steam Heaters

The water and steam are heated at different steps according to the
flue gas temperature. These include HP Economizer, HP Evaporator,
LP Evaporator and Superheater.
2.1.3 Drums
HP drum and LP Drum or LP separator tank are installed to separate
steam from water.
2.1.4 Pumps
These pumps are installed for the circulation of water and they
include HP Feedwater pumps or HP Evaporator recirculation pumps,
LP Feedwater pumps or LP Evaporator recirculation pumps, HP
Economizer recirculation pumps etc.
2.1.5 Soot Blowers
They clean soot deposits from the tubes on flue gas side of the
Boiler.
3.0 Steam Turbine

The Steam Turbine is a power unit which produces power from a
continuous action of steam on its turbine blades, the steam being
delivered to the turbine at a high pressure and exhausted to the
condenser at a low pressure.
Steam turbine converts the heat energy of superheated high-
pressure steam, coming from the boiler or HRSG, into rotational
mechanical energy. The conversion of energy in the turbine occurs
in two steps.
• First, the heat energy in the steam is converted into kinetic
energy of a steam jet by nozzles (stationary blades).
• Second, the steam jets blow on buckets or moving blades
mounted on a rotor to produce a mechanical force and torque.
The mechanical energy of the steam turbine is then used to drive a
generator to produce electrical energy. The steam turbine generator is,
by itself, a very simple machine with few moving parts. It is not unusual
for a steam turbine-generator to operate continuously for more than a
year without shutdown.
3.1 Main Components of a Steam Turbine

3.1.1 Turbine

12
The turbine converts the thermal and kinetic energy of the steam into
rotational mechanical energy. ST-15 Stage 1 Stage 2
has 26 stages of HP and 8+8 stages of
LP turbine and their sealing steam
system. There are two types of turbine
blades, Impulse and Reaction types.
Normally, turbine consists of
combination of impulse and reaction
types.
Turbine Principle
Steam enters the rotating channels
with absolute velocity ‘c’ with
reference to the fixed parts. When
magnitude and direction of both
velocities are known we get the
relative velocity ‘w’ with reference to
the rotating blades. Circumferential
velocity ‘u’ at rotating blade tip can be
calculated by the difference of ‘c’ and
‘w’.
c absolute velocity
w velocity in rotating
channel
U1 = C1 – W1
= relative velocity
u circumferential velocity Guide Rotating Guide
wheel wheel wheel
Indices
1 Inlet rotating wheel
Velocities in Steam Turbine Stages
2 Outlet rotating wheel
Impulse Type Turbine
U2 = C2 – W2
The basic idea of an impulse turbine is that a jet of steam from a

fixed nozzle pushes against the rotor blades and impels them
forward. The velocity of the steam is about twice as fast as the
velocity of the blades. Only turbines utilizing fixed nozzles are
classified as impulse turbines.

13
Reaction Type Turbine

A reaction turbine utilizes a jet of steam that flows from a nozzle on
the rotor. Actually, the steam is directed into the moving blades by
fixed blades designed to expand the steam. The result is a small
increase in velocity over that of the moving blades. These blades
form a wall of moving nozzles that further expand the steam. The
steam flow is partially reversed by the moving blades, producing
reaction on the blades. Since the pressure drop is small across each
row of nozzles (blades), the speed is comparatively low. So more rows
of moving blades are needed in a reaction turbine than in an impulse
turbine.
3.1.2 Condenser and Vacuum Pumps
It condenses steam when it finishes its work and exit from the turbine.
Vacuum pump regularly runs to evacuate any air accumulation in the
condenser.
3.1.3 Cooling Tower
This is provided to cool the close circulating water from the
condenser. It removes the latent heat of steam and converts it into
condensate.
3.1.4 Lube Oil system
It supplies lubrication and cooling for all bearings like compressor,
turbine, generator and supplies oil to the hydraulic oil system,
torque convertor and turning gear.
3.1.5 Generator
The generator is connected to the gas turbine. Generator converts the
mechanical output power of the gas turbine into electricity. When rotor
rotates in the stator, there is a relative motion between conductor and
rotor’s magnetic field. Voltage is induced by this relative motion into the
three coils of stator winding. When north and south poles of rotor
magnetic field pass before a stator winding then alternating currents of
sinusoidal (~) wave shape are produced. In this way three phase currents
are produced by the three phases of stator winding as shown in figure.
132 KV

14
The generator is air cooled in closed circuit. Generator output is at

11KV; it is stepped up by main transformer to 132 KV or 220 KV and
sent to WAPDA via transmission lines.
2.0Thermodynamic Cycles
2.1 Gas Turbine (Joule-Brayton) Cycle
The thermodynamic cycle of a gas turbine is referred to as the Joule-
Brayton Cycle (or simply Brayton Cycle). The four processes of the
Brayton Cycle are represented on a temperature-entropy (T-s)
diagram shown in figure. Entropy is a property of substances that
describes the availability of energy to do work. The T-s diagram is
useful in analyzing thermodynamic cycles because it reveals the
amount of heat required to make a process occur in a cycle. If a
process can be represented as a curve on the T-s diagram, the area
under the curve is the amount of heat required to make that process
occur.
Temperature
HEAT
ADDED Combustion
Expansion
HEAT (Turbine)
REJECTED
Four Processes of Gas

Turbine Compression
Brayton Cycle
Compression A-B
T-S Diagram
Combustion B-C
Expansion C-D
Each process
Heat Rejection
in
the
D-A
Brayton Cycle can be drawn on the T-s diagram.
The first process is the compression of Heat air in the compressor
represented by the line A-B. As the air is compressed, its
temperature and pressure increases and there is a corresponding
increase in enthalpy. As work is done on the air, the air stores this
energy in the form of temperature and pressure. The power (energy)
to perform this work originates from the turbine, which is directly
coupled to the gas turbine compressor through a common shaft.
The second process is the addition of heat to the cycle at a constant
pressure by burning of fuel represented by the line B-C. The
temperature of the gas that results from the combustion increases
considerably from the temperature of the air at the compressor outlet.
Normally air temperature at the compressor outlet is 300°C and the
flue gas temperature is increased up to 1000°C or 1300°C.

15
The third process is the expansion and cooling of the gas as it

passes through the turbine, is represented by the line C-D. Here, the
energy of the hot pressurised gas is used to perform work.
The final process in the Brayton cycle is the cooling of the hot gas
that exhausts to the atmosphere represented by line D-A. The
exhausted gas mixes with ambient air, thus decreasing in
temperature.
Amount of heat that is required to make Brayton cycle work is
represented by the area under lines B-C. The area under the line D-A
represents the fraction of heat that is rejected. The area between these
two lines represents the heat that is converted to useful mechanical
energy. The heat converted to useful mechanical energy is 20% to 25%
of the total heat required to make the process work.
2.1.1Thermodynamics of Gas Turbine Generator loss
(0.8 %)
The energy at the input is available as fuel STEP 4
(furnace oil or gas) and it represents

chemical energy. At the output we have Compressor
Mechanical loss
energy in the most valuable form as (0.5 %)
electrical energy. Electricity is easily Air
transported, easily controlled and easily
Exhaust
applied at all instances when energy is Heat Energy
used. There are several steps when energy (61 %)
is converted from its chemical form to Turbine

mechanical loss
electrical form: STEP 2 (0.5 %)
&3
Step 1: Chemical energy is converted Combustion Chamber
radiation loss (2 %)
to thermal energy (heat) in the STEP 1
form of a flow of hot "flue gases".

Step 2: Heat energy is transformed to FUEL
kinetic energy by increasing speed
of flue gases in nozzles.
Step 3: Flue gases act on rotor blades and rotate, in this way
kinetic energy is converted to mechanical energy.
Step 4: The mechanical energy is used to drive the generator
rotor, and it is converted to electrical energy.
Energy Conversion Processes :
Chemical Energy  Heat or Thermal Energy  Kinetic Energy 
Mechanical Energy  Electrical Energy
Now we look at first two steps more closely.
2.1.2Cyclic Process
These first two steps are only possible as parts of a thermodynamic
cyclic process because nature does not grant any gifts without being
paid; i.e. we must come back to the initial conditions where we
started.
Such a cyclic process describes how the fluid changes its state
during its flow through a given machine. State of the fluid can be

16
described by a couple of parameters which are inter-dependent.

These parameters are:
- Pressure P
- Temperature T
- Entropy S
We use these parameters to draw "T-S diagrams" which apply to the
actual fluid. For our present considerations we can use the T-S
diagram for air which is applicable for flue gas, too. In the range of
cyclic processes we commonly use the laws for ideal gases which are
valid here. By means of T–S diagrams
- cyclic processes can be made apparent
- cyclic processes can be evaluated how efficient they are
- we learn how the machine has to be designed in which a
given cyclic process takes place.
In the following we apply these three uses to our gas turbine
process:
2.1.3Gas Turbine Cycle of GT 1,2 & 13,14
The ideal gas turbine process normally
Temperature
applied named "Joule-Brayton - Cycle" is
defined by two isentropic and two isobaric
changes of state. °C
1000
Heat Input
(Combustion)
It begins at ambient conditions and an
isentropic compression of the fluid (air). It 800 Expansion
(Turbine)
means that the change of state of the

fluid is made at constant entropy, i.e. free 600 Specific Power available
at Coupling Flange
of any friction and free of any heat
transfer across the boundaries of the
machine. At the end of this ideal 400
compression, both pressure and
Evaluation of Energy
1 square is equivalent to
20 MW
temperature are increased but entropy 200
remained the same. Now heat is added to
100
the fluid by burning the fuel in the
Exhaust
Ambient Conditions
compressed fluid. Thus, entropy and 0 Entropy
temperature are increased but pressure -100
7 8
remained the same. Hereafter the flue kJ
Ideal Joule – Brayton Cycle kg °K
gas is expanded during an isentropic
change of pressure and temperature. The flue gas is now at ambient
pressure again but at elevated entropy and elevated temperature.
In order to complete the cyclic process the flue gases are blown into the
atmosphere and the energy content is dissipated, i.e. wasted. This is
the price we must pay for having converted the energy from a lower to
a higher value.
2.1.4Evaluate

17
The T-S diagram is handy for representing energy and heat per fluid
mass unit. These values appear as areas; e.g. 1 square shown on the
T-S diagram is equivalent to 20 MW.
It means, that if we know the mass-flow we can easily calculate
- the power available at the coupling flange
- the heat to be put in
Flue gas mass flow:
Unit 1, 2 Unit 13, 14 Unit 3, 4 Unit 5-8
426 Kg/sec 471 Kg/sec 322 Kg/sec 406 Kg/sec
2.2 The Steam-Water (Rankine) Cycle

The Rankine Cycle used in conventional steam power plants can be
represented on a T-h diagram. As with the Brayton Cycle, each line
segment corresponds to a process in the cycle. A simple Rankine
Cycle consists of only four components; the boiler (often called a
steam generator), a turbine, a condenser and a boiler feed pump.
Boiler is shown with a superheater, thus the steam entering the
turbine is above saturation temperature.
Super
heater HEAT HEAT
3 4 ADDED REJECTED
Steam Super
Turbin 5
heater
e T
Boiler Boiler
Steam
Turbin
e
2 Boiler
Feed
Condenser Pump
1 Condenser
Boiler
Feed
h
Pump
Figure: Rankine Cycle T-h
diagram
The first process in Rankine Cycle (Line 1-2) is the increase in
pressure of condensate from condenser by the boiler feed pump.
Increase in pressure occurs with a slight increase in enthalpy (h).
The second Rankine Cycle process (Line 2-3) is the addition of heat
to water entering the boiler. Within the boiler, the water is
transformed from a liquid to steam (a gas). The generation of steam
is assumed to occur at a constant pressure. Additional energy is
added to steam as it passes through the superheater (Line 3-4).
Steam is then expanded and cooled as it passes through the turbine
as represented by Line 4-5. Here, the energy of steam is used to
perform work.
The last process in the Rankine Cycle is the condensation of steam
that exhausts from the turbine, represented by line 5-1. During

18
condensation, considerable heat, called the latent heat of

vaporization, is lost.
The heat required to make the Rankine Cycle work is determined by

the area under the lines between points 2 to 4; and the heat lost from
the cycle is under the line between points 5 and 1. The area between
the lines represents the heat that is converted to useful mechanical
energy. The useful mechanical energy is only about ⅓rd of the heat
required to make the cycle work.
The efficiency of conventional steam power plants is about 30% to

35%. Actual steam power plants are considerably more complex
than the simple cycle shown in Figure, because components such as
Condensate pump, Feedwater tank, Economizer, LP & HP Feedwater
heaters and Air preheater are added to improve efficiency. Typically
only 85% to 90% of the heat energy input is absorbed in Boilers.
This means that the boiler is only 85% to 90% efficient. Additional
auxiliary equipment, such as fans and soot blowers, use part of the
power produced usually around 5%.
2.2.1Actual Steam - Water Cycle / T-s diagram
The T-s diagram (Fig 4.3) illustrates the thermodynamic conditions
and parameters in the actual water- steam cycle.
Clausius established entropy in mathematic formulas in order to
determine transformability of heat energy. Later on Belpair found
that principle of entropy can be presented by areas of transferable
amounts of heat in the T-s diagram.
If one follows the various stages of the water-steam cycle, they can
be presented in the T-s diagram. The area below the curve depicts
the supply or release of heat energy in order to reach a new
condition. The temperature axis must then however be extended to
the absolute "0 °K" point. In calculations temperatures are stated in
Kelvin, which means the origin in the diagram is 0 °K (- 273.15 °C).
The region of wet steam can be easily recognized in the T-s diagram.
The hill, the left margin of which equals x = 0, that is pure water, is
remarkable. The right curve represents saturated steam ( x = 1). All
points in between these margins depict wet steam with a certain
share of water.
One must be careful, because the diagram shows the specific
entropy ‘s’ in units of kJ/kg/°K. So you should keep in your mind, that
the shown values of entropy are good for 1 kg of the media at the
given point.
This T-s diagram shows the turbine cycle all over the Plant i.e.
Steam Turbine and HRSG. It starts with the condenser outlet to the
feedwater tank. The area underneath this line is the amount of heat
brought to the cycle from the LP evaporator into the feedwater tank
by the LP steam.

1 2 3 4 5 6 7 8 9
600
T [°C] h [kJ/kg]
v [m3/kg] Outlet
p [bar] Superheater
Values at Triple Point:

500 p = 0.006112 bar
T = 0.01 °C
s = 0.00 kJ/kg/°K (arbitrary)
Values at Critical Point:
p = 221.2 bar (3206.2 psia)
T = 374.15 °C (705.4 °F)
v = 0.00317 m3/kg
400 h = 2107.4 kJ/kg 400
s = 4.4429 kJ/kg/°K
(0.00 °C = 273.15 °K)
300 300
T = Temperature
HP-Drum
Inlet
HP-Drum
Outlet
HP-Turbine
Outlet
200 200
Feedwater
Tank
100 100
Condenser
Outlet
Condenser
Inlet
0
1 2 3 4 5 6 7 8 s [kJ/kg/°K] 9
s = Specific Entropy
Prepared by: Fazal-ur-Rehman Babar

20
The area underneath the line feedwater tank to HP drum inlet shows
(theoretically) the amount of heat drawn from the exhaust gases by the
economizer. The HP evaporator draws the heat underneath of the
horizontal line in between HP drum inlet and HP drum outlet. The
superheating is done nearly at the same pressure, but up to higher
temperature. The steam condition becomes far away from the saturated
condition, so the end of the turbine gets better conditions concerning the
arising of water. Due to the heat transfer for superheating the enthalpy
will rise too, gives the turbine a higher "capacity of work".
The arising heat underneath of the line "outlet superheater" to
"condenser inlet" is the heat, Clausius was thinking of Conversion of
heat energy into mechanical energy causes a rising of the entropy,
which is sometimes explained as an arising of losses. These losses in
that connection are losses due to "intermolecular friction", not
losses to the environment.
The amount of heat shown underneath the line "condenser inlet" to
"condenser outlet" has to be given to the environment to
condensate the steam of the turbine and to close the circuit. To
calculate the real amount of heat, one has to multiply this value with
the actual mass flow.
2.3The Combined Cycle
Gas Turbine Steam Turbin
Combined cycle is a power plant in Cycle ce Cycle
which consists of a gas turbine, Boiler
and a Steam Turbine. In this cycle a Heat
Rejected
gas turbine is connected to a steam
turbine via a boiler. The steam turbine
cycle makes use of much of the heat in
the gas turbine exhaust gases.
Thermodynamically, the combined
cycle can be represented by joining
the high temperature Brayton cycle
with the moderate pressure and
temperature Rankine cycle. An
example of a combined cycle showing Combined Cycle T-h Diagram
the Brayton cycle (gas turbine) and the Rankine cycle (steam turbine)
on a T-h diagram is shown in Figure.
The area enclosed by the Rankine cycle is within the area that
represents the heat rejected from the Brayton cycle. Thus, the
Rankine cycle area represents the heat energy that is converted to
useful mechanical energy that would other-wise be rejected to the
atmosphere. A large portion of the heat lost from the Brayton cycle is
used in the Rankine cycle. A much greater fraction of the heat added
to the cycle is actually converted to useful mechanical energy in the
combined cycle than either the Brayton cycle or the Rankine cycle
alone. The Rankine cycle parameters (pressure and temperature) are
selected to match the temperature of the available gas turbine
exhaust gases. Usually, the pressure and temperature used in the
Rankine cycle portion of the combined cycle plant are much lower

21
than those used in conventional Rankine cycle plants. The lower

pressure and temperature are necessary because the gas turbine
exhaust gas, while very hot, is not nearly as hot as the flue gas
entering the convection pass of a conventional fuel fired boiler.
The challenge in joining the Brayton and Rankine cycles in a
combined cycle plant is the degree of integration needed to
maximize efficiency at an economic cost. The simple combined cycle
can consist of a single gas turbine, HRSG, steam turbine, condenser
and auxiliary systems. In addition, if the environmental regulations
require, an emissions reduction system can be directly integrated
within the HRSG.
Advantages of a Gas Turbine

1. Its operation is simple, can be started quickly and can be put on
load in very short time. For these reasons, gas turbine power
plants are able to meet peak - load demand, such as at evening
peak.
2. They require lower capital investment and occupy less space.
The starting cost of the plant is lower than equivalent steam
power plant.
3. The time required for their construction is short. The plant does
not require heavy foundation and a large building.
4. The maintenance of the plant is easier and maintenance cost is
lower.
5. The lubrication of the plant is easy. In this plant lubrication is
needed mainly in compressor bearing, turbine bearing and
bearing of auxiliary equipment.
6. The gas turbine power plant requires less water as compared to
condensing steam power plant.
7. Gas Turbine auxiliary consumption is very less and there are
very little standby losses in the gas turbines as compared to a
Steam Turbine.
8. There is a great simplification of the gas turbine power plant
over the steam turbine power plant due to less auxiliaries and
absence of boilers with their feed water evaporator and
condensing system.
Disadvantages of a Gas Turbine

1. Major part of the work developed in the turbine, about 60%, is
used to drive the compressor. The remainder of the turbine work
is available to produce power by driving a generator. Therefore
network out put of the plant is lower.
2. For it starting purpose starting motor is required.

22
3. Since the temperature of the parts in the combustion becomes

too high, so services conditions become complicated even at
moderates pressures. Similarly, the first stage turbine blades
face high temperature flue gases, therefore these are made with
special material and these are coated with high temperature
material.
4. On open cycle its thermal efficiency is low and it is about 34%.
However in combined cycle mode the overall thermal efficiency
is can be even higher than 45%.
General Definitions
a. Newton
The force required to give a mass of 1 Kg an acceleration of 1
m/sec 2 .
b. Joule
Work done is 1 joule when a force of 1 Newton moves a body by
1 meter.
(1 joule = 1 Newton-meter).
c. Watt
Power is the rate of doing work. One watt is the power or rate of
doing work when 1 joule of work is done in 1 second. (1 watt = 1
joule/sec).
d. Calorie
The calorie is the quantity of heat required to raise the temperature
of one gram of water one degree centigrade (more accurately, from
15.5 to 16.5 °C).
The multiple is the kilocalorie, quantity of heat required to raise
the temperature of 1000 grams of water one degree centigrade.
The "thermie" equal to 1000 kilocalories, is the quantity of heat
required to raise the temperature of 1000 kilograms of water one
degree centigrade
e. BTU (British Thermal Unit)
BTU is the quantity of heat required to raise the temperature of
1 pound (1lb) of water by one degree Fahrenheit (1°F) (more
accurately, from 63.5 to 64.5° F).
1 BTU = 252 calories = 0.252 kilocalorie
f. Calorific Value
It is the heat evolved by burning a unit mass of fuel. For
example 40,200 kJ of energy is released when one kg of Furnace
Oil is burnt and 32,400 kJ of energy is released when 1 M 3 of Gas
is burnt.
g. Fuel Equivalent
210 Ton Fuel Oil = 9.9 MMCF of Gas = 1 GWh
h. Specific Heat

23
The specific heat of a substance is the heat in calories required

to raise the temperature of one gram of the substance one
degree centigrade.
In effect there are two sorts of specific heat:
i. Cv - specific heat at constant volume,
Quantity of heat required to raise the temperature of the mass
unit of the gas, one degree centigrade, at constant volume.
j. Cp - specific heat at constant pressure,
Quantity of heat required to raise the temperature of the mass
unit of the gas, one degree centigrade, at constant pressure.
Note: the ratio Cp/Cv generally is labeled γ .
Besides, it is important to note that in the processes that
constitute the thermodynamic cycle of a gas turbine, Cp can be
considered as constant.
k. Latent Heat
It is the heat used to change the state of a substance e.g.
change of state from water to steam at the same temperature in
HP evaporator. Similarly it is the heat rejected (to cooling tower)
in condenser when turbine exhaust steam at 40 °C is converted
to water (condensate) at the same temperature.
l. Entropy (S)
It is the heat quantity evolved in a process when the
temperature considered uniform during the process. S is
expressed in calories per degree centigrade.
m. Enthalpy (h)
It is the heat supplied to the fluid at constant pressure. It is
measured in kJ/kg. The fall of enthalpy is equivalent to
mechanical work output.
n. Net Power and Work Output (P, W)
are those available at generator terminals.
o. Power and Work at Turbine Flanges (P f , W f )
are those directly available from the sole engine, before
reduction gear, auxiliaries, etc.
p. Specific Power (P s )
is the power output for each mass flow unit running the cycle.
q. Specific Work (W s )
It is the work obtained from the mass unit running a cycle.
r. Mechanical Efficiency ( η m )
is the ratio between the work output at turbine flange and the
internal work of the gas on the blades.
s. Combustor Efficiency ( η b )

24
is the ratio between the heat actually supplied to the gas in the
engine combustion system and the heat that a fully burned fuel
should have released.
t. Overall Efficiency ( η g )
is the ratio between the net power output and the product of
fuel flow multiplied by its lower heating value.
u. Heat Rate (HR)
is the inverse of the Overall Efficiency. It is the heat in BTU or kJ
required to generate 1 kW of energy.
v. Thermal Efficiency ( η t )
1 where:
η t=1– rp = pressure ratio
rp(1– 1/γ ) γ = 1.4 (a constant for flue
gas)
This equation shows that thermal efficiency depends upon
pressure ratio only which relates to the compressor.
w. Exhaust Temp Calculation

k
CPD
Tf = Tx ×
Patm
This equation shows that thermal efficiency depends upon

pressure ratio only which relates to the compressor.
x. Pressure Ratio
It is the ratio of compressor discharge pressure to the inlet
pressure;
Pressure ratio rp P2
= P1
y. Work Ratio
It is the ratio of Net work and Gross work;
Net work work of expansion – work of
Work ratio
Gross = compression
=
work work of expansion
Electrical definitions
a. Coulomb (C)
It is the quantity of charge of 6.02 × 10 23 electrons or protons.
b. Ampere (A)
It is the unit of current and it is equal to 1 coulomb charge
flowing in 1 second.
1 Ampere = 1 Coulomb/sec.
c. Volt (V)

25
The potential difference is 1 Volt if 1 Joule of work is done for

moving 1 Coulomb of charge between two points. (1 V = 1 J/C).
d. Ohm (Ω)
It is the resistance in which a dc current of 1 Ampere generates
heat at the rate of 1 joule/second (1 watt).
e. Watt (W)
It is the unit of power (P). Between two points if the potential
difference is 1 volt and current is flowing 1 Ampere then the
electrical power is 1 watt. (P = V I). 1 kW = 1000 watt. Domestic
electric energy meters measure electricity in kWh (1 Unit = 1
kWh), it means 1 Unit of electricity is consumed if an electric
iron of 1000 watt work for 1 hour or if a bulb of 100 watt light
for 10 hours.
Gas Turbine Terminology

Turbine
It is a mechanical component in which the thermal energy of the
working medium is converted to mechanical energy by kinetic
action on a rotary element.
Single shaft turbine
Such turbine in which turbine and compressor are on one shaft
is called single shaft turbine.
Turbine stage
It consists of a set of stationary nozzles and one row of moving
blades which are mounted on one disc.
The flue gas expands through the stationary nozzles to a lower
pressure, thus releasing kinetic energy which is absorbed by the
moving blades.
Turbine rotor blades or Bucket (GT 5-8)
Aerofoil sections mounted on a rotor disc and proportioned to
transfer energy from the flue gas volume to the turbine rotor.
Turbine stationary blades or Nozzles (GT 5-8) or Diaphragm (GT 3,4)
A stationary element of the turbine blades used to expand the
flue gas and increase its velocity by reducing pressure and
direct it against the rotating blades.
Axial compressor
The mechanical component through which the air pressure is
increased.
Compressor blades
Aerofoil sections mounted on a disc and proportioned to press
the air through each successive row of compressor stationary
blades or diaphragms.
Compressor stationary blades or diaphragms
A stationary element containing a set of stator blades used to
compress the air and direct it towards the rotating blades.

26
Combustor basket
The mechanical component of the combustion system in which
the fuel is burnt to increase the temperature of the flue gas.
Transition piece
Mechanical component which directs the hot gases from
combustor basket to the segmental opening leading to the
turbine inlet.
Fuel nozzle
The component of the combustion system which meters the fuel
to the combustor basket with the proper dispersion pattern.
Igniter
The component of the combustion system which at a pre-
determined point is energized to provide the spark for igniting
the fuel in the combustor basket.
Cross flame tube
A mechanical interconnection between combustor baskets for
the purpose of carrying the flame from a fired to an unfired
combustor basket.
Temperature control system
Under any normal conditions of operation, it limits input fuel as
necessary to prevent the temperatures in the turbine from
exceeding allowable limits.
Turbine temperature detector
That component of the control system which senses the
temperature of the flue gases and provides the signal to limit
the fuel input to the combustor baskets when maximum pre-
determined temperature is reached.
Ignition speed
The speed of the compressor shaft at which ignition and fuel are
applied.
Self-sustaining speed
The minimum speed of the compressor shaft at which the
turbine will continue to operate at no-load without cranking
power.
Idling speed:
The specified operating speed of the compressor shaft for no-
load operation.
Rated speed
The speed of a designated shaft at which it runs on load.
Trip speed
The speed at which the overspeed protective device operates.
Cranking speed
The speed at which the turbine is rotated for washing.
Starting power
The external power which is required to accelerate the
compressor, its turbine, and any connected load to self -
sustaining speed in a specified time.
Journal-bearing

27
This bearing is used to support the rotating elements (shaft) and

it maintains the radial position of the rotor with respect to the
stator.
Thrust bearing
This bearing supports the axial thrust of the rotor to the bearing
housing and it maintains the axial position of the rotor with
respect to the stator.
Bearing housing
An enclosure used to contain and support the shaft bearings and
may be of the bracket or pedestal type.
Interstage seals
Mechanical device used to restrict the leakage of the air or flue
gas between stages.
Compressor bleed valve
An open-close line used to blow off a portion of the air from a
stage of compressor during a start-up or a shut down period.
Rotor assembly
This is the rotating element of the gas turbine which includes all
parts attached on the shaft and has provision for coupling.
Discs or Wheels
They constitute the gas turbine shaft. On these discs the
rotating blades are assembled.
Wheel space or Disc Cavity
It is the space between rotor wheel and diaphragm of the stator
blade. Here thermocouples are placed to measure the
temperature.
Shroud or Seal
A shaped metallic strip next or connected to the blades in order
to limit the leakages.
Governing system ;
which includes but it is not limited to:
• Speed governor on the load shaft with load setting device for
manual operation at the machine and/or control panel
• Check of turbine maximum over-temperature
• Emergency over-speed governor on the load shaft.
Speed governing system
A system of control elements and devices for the control of the
speed or power output of a gas turbine and includes a speed
governor, speed changer, fuel control mechanism, and other
devices and control elements required to actuate the fuel
control valve.
Speed governor
The primary speed-sensitive element which is directly
responsive to speed and which positions or influences the action
of other control elements.
Fuel control mechanism
This mechanism controls the flow of fuel to the gas turbine.
Speed changer

28
Used to change the setting of the speed governing system for

the purpose of adjusting the speed and/or load of the gas
turbine during operation.
Control panel
A component on which are mounted the devices used to
regulate and monitor the necessary functions for safe operation
of the gas turbine.
Controlling device
One which automatically initiates action of a system which
controls conditions during the normal operation of the gas
turbine.
External control device
An element which is responsive to signals that are external to
the gas turbine. It may be pneumatically, hydraulically or
electrically actuated from the signal source and acts to control
the energy input to the gas turbine.
Protective device
One which, alone or as part of a system, controls or signals in
some predetermined manner, abnormal conditions which may
occur during the operation of the unit or system to which it is
connected.
Warning device
One which by visible or audible means, or both, indicates that
an abnormal operating condition exists.
Baseplate (bedplate)
A structural metal frame for supporting the gas turbine and its
auxiliaries as a unit.
Inlet silencer
The elements system which decreases the sound power level
transmitted by the air at the inlet of the compressor.
Exhaust silencer
The elements system which decreases the sound power level
transmitted by the flue gases leaving the gas turbine.
Auxiliary gear or Accessory drive
Converts the gas turbine speed to the speed required by the
auxiliary equipment.
Accessories
Apparatus deemed necessary for the proper functioning and
safety of operation of the gas turbine.
Starting equipment

29
The starting equipment shall be capable of bringing the gas

turbine up through the normal starting cycle to self-sustaining
speed.
Turning gear
The turning gear rotates the gas turbine rotor at low speed prior
to starting and immediately after shut-down to assure uniform
temperature distribution in the rotor.
Heat Recovery Steam Generator or Exhaust heat boiler
Used to recover and transfer heat from the flue gases leaving
the gas turbine to generate steam or hot water.
Lubricating system ;
Closed forced-feed system including the following:
• Oil tank of sufficient capacity and oil piping
• Tank oil level indicator
• Main oil pump-sized to supply oil requirements for the complete
gas turbine unit during normal operation
• Auxiliary and Emergency lube oil pumps with means for testing their
operation
• System for automatically activating emergency and auxiliary lube
oil pump
• Temperature measuring device in the oil feeding manifold
• Lube oil coolers
• Pressure gauge on oil feeding manifold
• Relief valves
Supervisory instrumentation ;
Electro-pneumatic system for checking and monitoring of unit
performances. It include
• Master control switch for semi-automatic start and for stopping
the gas turbine
• Speed changer checking system
• Relay to provide the necessary functions of control and
protective operations of the gas turbine
• Starting and sequence indicating lights
• Temperature indicator for the turbine exhaust temperature
• Speed indicator for output shaft
• Loss of flame indication
• Annunciator with audible alarm and individual malfunction
indicators for overspeed, flameout, low lube pressure, high
bearing oil temperature and high turbine cooling water
temperature
• Pressure gauges for measuring lube oil manifold pressure, fuel
pressure, overspeed oil pressure and control air pressure.

30
G AS T U R BDI NE SE ISG N DATA:

Description Unit 1, 2 Unit 13, 14 Unit 3, 4 Unit 5-8
Gas Turbine
Model V-94.2 V-94.2 TG-50 MS 9001 E
Manufacturer Siemens (Germany) Siemens (Germany) FIAT M/S ALSTOM
M/s GIE (Italy) France
Control ISKAMATIC TELEPERM Conventional relay Mark IV
EA/EHF type; Fiat Hi Tech Speedtronic control
Design Load 114.75 MW 97.1 MW
Base Load rating 94 on GAS 110 / 107 on Gas 84 / 83 on GAS 80/79/80/80 on Gas
according to IDC 91 on HSD 105 / 103 on HSD 83 / 84 on HSD 76/76/77/76 HSD
test in 1996 91 on FO 105 / 103 on FO 76/76/77/76 on FO
Base Load rating 94 on GAS 110 / 107 on Gas 84 / 83 on GAS 80/79/80/80 on Gas
according to ADC 91 on HSD 105 / 103 on HSD 83 / 84 on HSD 76/76/77/76 HSD
test 91 on FO 105 / 103 on FO 76/76/77/76 on FO
Starting time upto 4 Minutes 4 Minutes 25 Minutes 10 Minutes
3000 RPM
Spining Reserve 20 MW 20 MW 2 MW, after 90 Sec 4 MW
Auto Loading 11 MW/minute 11 MW/minute 6 MW/minute 8 MW/minute
gradient upto base load upto base load
App. net thermal 26 % 29 % 25 % 27 %
efficiency (open cycle) (open cycle) (open cycle) (open cycle)
Critical speed 1500 – 1850 rpm
Turbine
Turbine Stages 4 4 4 3
Max. Turbine Inlet 1050 °C 1050 °C 1050 °C 1050 °C
Temperature
Turbine exhaust 500 to 530 °C 500 to 550 °C 550 to 610 °C 480 to 550 °C
temp. at full load
Heat rate (kJ/kWh) 11,200 on Gas
11,300 on HSD
11,600 on BFO
Flue gas mass flow 426 Kg/sec 471 Kg/sec 322 Kg/sec 406 Kg/sec
Fuel flow (kg/s) 8.73 on Gas
9.28 on HSD
8.55 on BFO

Compressor
Compressor Stages 16 16 20 17
Discharge pressure 1-9 bar 1-9 bar 1-9 bar 1-9 bar
varies acc to speed
Compression Ratio 9.11 9.11 12 9.11
Inlet guide vanes Fixed Variable,modulated Variable,modulated Variable,modulated
at 34°, 57°, 84°
Bleed valves № 1.1 is electric № 1.1 and № 1.2 3, 4, close with comp
operated, are air operated, № 1, stage 6 close discharge air &
№ 1.2 is air and both are at above 2800 rpm. open with spring.
operated and both stage 5, these close № 2, stage 12 close All close at 95%

31
are at stage 5, these above 2940 rpm. above 2700 rpm. speed
close above 2950rp. № 2 is air operated, № 3, stage 15 close
№ 2 is air operated, at stage 10, close above 1900 rpm
at stage 10, close above 2280 rpm
above 2300 rpm
Starting System
Starting Device S.F.C S.F.C 11KV – 1915 KW 6.6KV – 1000 KW
Max. startup rating Max. startup rating
2900 kW 2900 kW
Declutching Speed 2100 to 2300 RPM 2100 to 2300 RPM 1910 to 1980 RPM 1800 RPM
Combustion and Fuel System
No of Combustors 2 2 18 Nozzles 14 reverse flow
Fuel Nozzles/ 8 per combustion 8 per combustion 1 per combustor 1 per combustor
Burners chamber chamber
Spark Plugs 1 for each nozzle 1 for each nozzle 2, located at
2, electrode type,
burners 12 & 13.
spring-injected,
self-retracting,
located at burners
12 & 13.
Flame detectors 2, one at each left 2, one at each left 4, ultra-violet type, 4, ultra-violet type,
and right chambers and right chambers FD1,2 at nozzle 1, located at burners 3,
FD3,4 at nozzle 18. 4, 5 & 11.
Fuel pump 1, Electric motor 2, Electric motor 1, Electric motor 1, Accessory gear-
driven. Fixed driven. Fixed driven. Fixed driven, Fixed
displacement, displacement, displacement, displacement, screw
screw type pump screw type pump screw type pump type pump
Flow divider - - Ram type Circular, free
wheeling,
14 elements
Fuel oil emergency Open by hydraulic Open by hydraulic Air operated Open by electro-
stop valve (ESV) control oil, close by control oil, close by hydraulic servo
spring force spring force control oil, close by
spring force

Combustion and Fuel System
Fuel oil control At return line, At return line, Air operated VC 3 Fuel bypass
valve hydraulic control hydraulic control valve and flow
divider control the
fuel oil flow
Fuel oil pressure 6-7 bar 6-7 bar 5-6 bar
low
Fuel oil pressure 65 bar 65 bar 65-70 bar 65-70 bar
high
Dosing pumps 2 pumps with low 2 pumps with low 2 pumps with low 2 pumps with low
and high range and high range and high range and high range
Lubrication System
Lube Oil Grade TRESSO-46 TRESSO-46 TRESSO-32 DTE-724

32
Total Oil Capacity 11.4 m3 13.5 m3 10.5 m3 3,300 gallons or

12,540 litres
Max. Oil Level 320 mm from top 320 mm from top
12.13 m3
Min. Oil Level 440 mm (from top 440 mm from top
of oil tank) 10.54 m3
Main lube oil pump One AC motor No. 1, AC motor 2, AC motor driven 1, accessory gear
driven Press = 5 bar driven Pressure = 4-5 bar driven, Pressure
Auxiliary lube oil 1, AC motor driven No. 2, AC motor Any one can be 1,AC motor driven,
pump driven selected as main vertical,submerged,
and other standby centrifugal type
Emergency lube oil 1, DC motor driven 1, DC motor driven 1, DC motor driven DC motor driven,
pump Pressure = 1.2 bar Pressure = 1.2 bar Pressure = 1.2 bar vertical,submerged,
centrifugal type
Jacking oil pump 1, AC motor driven 1, AC motor driven Nil Nil
Pressure = 140 bar Pressure = 140 bar
Bearings at Compressor, Turbine and Generator Rotor
Quantities 2+2 2+2 2+2 3+2
Lubrication Pressure lubricated Pressure lubricated Pressure lubricated Pressure lubricated
№ 1 bearing MBD11, Journal MBD11, Journal Located in inlet
Located at Turbine Located at Turbine casing assembly,
Exhaust Exhaust Active and inactive
thrust
Journal Elliptical
Active thrust Tilting pad,
self-equalizing
Inactive thrust Tilting pad,
non-equalizing
№ 2 bearing MBD12, Journal + MBD12, Journal + Located in
Thrust, Located at Thrust, Located at compressor
Compressor air Compressor air discharge casing,
Intake Intake Elliptical journal

№ 3 bearing MKD11, Located at MKD11, Located at Located in exhaust
Generator on Generator on frame, Journal,
Compressor side Compressor side tilting pad
№ 4 bearing MKD12, Located at MKD12, Located at
Generator on slip- Generator on slip-
ring side ring side
Hydraulic supply system
Main hydraulic - - Accessory gear
supply pump driven, variable
positive
displacement, axial
piston
Auxiliary hydraulic - - AC motor driven
supply pump 88HQ
Control oil system

33
Booster oil pump 1, AC motor driven 1, AC motor driven 2, AC motor driven -

Press = 8-9 bar
Atomizing air system

Main compressor no air atomizing no air atomizing Accessory gear
fuel burn, pressure fuel burn, pressure driven 51,000 rpm,
atomization atomization centrifugal type
Starting (booster) - - - Axial flow, positive
compressor displacement, belt
driven by ACmotor
Air pre-cooler - - - Water-to-Air heat
exchanger
Data from Performance Section

Fuel Calorific Values Sui Gas : 32,400 kJ/m3,
HSD : 36,300 kJ/Ltr
FO : 40,200 kJ/kg
Net Complex Output (MW) in IDC 1996 1345 MW
Net Complex Output (MW) in ADC 2004 1360 MW
Maximum Generation in a Month (April 2004) 789,665 MWh
Maximum Generation in one day 35,667 MWh
Maximum Plant Load 1541 MW
Conversion
1 mm of Water Column 2.81 mbar; 2.107 mm of Mercury
1 bar (= 1 M water column) 14.7 PSI = 100,000 Pascal
3412 BTU = 3600 kJ 1 kWh

34
S T E A M T U R B IN E S D E S IG N D A T A :
Description Unit 9, 10 Unit 11, 12 Unit 15
Steam Turbines
Make ABB, Germany RATEAU, France SIEMENS, Germany
Type DK 2056 VEGA 209 110 B 030-16, N30-2X5-B-9
Rated Power 112.2 MW 103.4 MW 148.6 MW
No. of Cylinders 2 1 2
First Cylinder
Stages 16 Reaction 12 HP, 5 LP 26 Reaction
Second Cylinder
Stages 7+7 reaction double flow - 8+8 reaction double flow
HP steam inlet 47.9 bar 40 bar 57 bar
pressure
Temperature 495 °C 510.8 °C 528 °C
LP steam inlet pres 3.99 bar - 5.78 bar
Temperature 190.6 °C - 221 °C
Vacuum 0.091 bar (a) 0.091 bar (a) 0.091 bar (a)
Turning Gears
Make ABB, Germany FLENSER, France KWU, Germany
Drive AC motor driven AC motor driven 57 bar
reduction gear reduction gear
Turning Speed 43 rpm 50 rpm 58 rpm
Condensers
Make ABB, Germany DELAS KWU
Type Spring mounted surface Rigid mounted surface Rigid mounted surface
condenser condenser condenser
Water passes 2 2 2
Cooling Area 8204 m2 8651 m2 9982 m2
Circulating water 5.690 m3/sec or
flow 20,484 Ton/hr
Vacuum 0.091 bar (a) 0.091 bar (a) 0.091 bar (a)
Total steam flow 110.551 Kg/sec 97.64 Kg/sec 128.04 Kg/sec
CW flow 4681.6 Kg/sec 4626 Kg/sec 5650.1 Kg/sec
CW vel in tubes 1.91 m/sec 1.95 m/sec 1.9 m/sec
CW inlet temp 29 °C 30 °C 28.5 °C
Cond pres loss 0.38 bar 0.46 bar 0.41 bar
No. of tubes 13000 12532 16032 + 1236
Tube outer dia 24 mm 24 mm 23 mm
Tube thickness 1 mm 1 mm 1 mm & 0.7 mm
Tube Material CuZn28Sn Admiralty Brass CuZn28Sn1F32
X 2CrNiMo Stainless Steel X 2CrNiMo N17135
Corrosion prot for Rubber Lined Epoxy Paint Epoxy Paint
Water Box

35

Circulating Water Pumps
Make TORISHIMA KSB TORISHIMA
Type 1200-SPB PHZ 900-990 SPV 1200
Flow 9630 Ton/hr 8360 Ton/hr 11320 Ton/hr
TDH 23.2 m 17.2 m 22.3 m
NPSH 5m 3.5 m 12.3 m
Speed 325 rpm 590 rpm 295 rpm
Power 920 KW 462 KW 1000 KW
Material
Casing JIS FC25 Cast Iron JIS FC 250
Shaft JIS S45C Carbon Steel JIS S45C
Impeller SCS1 Bronze GCu SN10 SCS1
Condensate Pumps
Type WKTA-200/2 FEX.36-3 12QLQC 21/60/3
Flow (t/h) 403.1 422 465
TDH (m) 75.6 96 195
NPSH (m) 3.3 33.4 2.5
Speed (rpm) 1480 1480 1480
Power (kw) 130 KW 150 316
Material
Casing JIS SCPM 2 A420CM ASTMA 48 CL.35
Shaft JIS SUS42OL2 Z15CN16-02 ASTMA 276-410
Impeller JIS SC51 Z4CND13-412 ASTMA 743CA6NM
LP Feedwater Pumps
Make TORISHIMA INGERSOL DRESSER WORTHINGTON
Type RPK50-400 ERP100-200 HED
Flow (t/h) 30 175 39.24
Head (m) 190 6.7 20
NPSH (m) 1.9 7.8 0.884
Speed (rpm) 2945 2950 2980
Power (kw) 55 30.1 65
Material
Casing JIS SCS1 A216GrWCB A216 GR WCB
Shaft JIS SUS420J2 A193GrB7 A276 – 410
Impeller JIS SCS1 A473CA6NM A487 GR – CA6NM

36
HP Feedwater Pumps
Make TORISHIMA BYRON JACKSON WORTHINGTON
Type HGC 4/8
Flow (t/h) 206.9 183.5 337
Head (m) 831.2 675 933
NPSH (m) 6 6.51 10.50
Speed (rpm) 2970 2980 2980
Power (kw) 671 1200
Material
Casing SFVE2 A743-CA-6MM A 487 GR CABNM
Shaft 13CR A276-TP410 A 276 TY 410
Impeller SCS1T2 A743-CA-6MM A 487 GR CABNM
Vacuum Pumps
Make SIEMEN HIBON SIEMEN
Type 2BW4303-0=OML49 SHR215006H00.950 2BE 1303-OZY4Z
HOGGING OPERATION
Suction Pressure 0.3 bar 0.39 bar 300 mm bar
Design Flow 5200 m3/h 25.5 kg/h 30 Kg/hrs
Rated Power 65 kw 42 kw
HOLDING OPERATION
Suction Pressure 0.0326 bar 0.083 bar 0.1 bar
Suction Temp. °C 40 44 100
Design vapor
mixture flow 37.3 Kg/h 108 Kg/h 67.5 Kg/h

37
G E N E R A T O R S
Description Unit 1,2 Unit 3,4 Unit 5-8 Unit 9,10 Unit 11,12 Unit 13,14 Unit 15
Type TLRI SGTIC T 229-320 WX 21L- T-229-320 TLRI TLRI
108/41 243704 064LL 108/36 108/41
Make KWU ERCOLE ALSTHOM ABB ALSTHOM KWU KWU
MARELLI
Rated Out Put 135 87 125.95 132 121.647 170 175
(MVA)
Power Factor 0.85 0.85 0.85 0.85 0.85 0.85 0.85
Rated Voltage 10.5 11.0 11.5 11.0 11.5 11.0 11.0
(KV):
Rated Current (A) 7423 4567 6223 6928 6107 8923 9185
Frequency (HZ) 50 50 50 50 50 50 50
Speed (RPM) 3000 3000 3000 3000 3000 3000 3000
Over Speed Limit 3600 3600 3600 3600 3600 3600 3600
(RPM)
Field Voltage (V) 333 142 151 236 146 432 432
Field Current (A) 641 810 2110 1495 2011 946 865
Short Circuit Ratio 0.5 0.6 0.51 0.5 0.58 0.502 0.534
Direct-Axis sub- 0.148 0.114 0.195 0.17 0.175 0.183 0.176
transient Reactance
(Xd″ ) per unit
Direct-Axis 0.242 0.145 0.275 0.26 0.252 0.304 0.286
Transient
Reactance (Xd′ )
per unit
Direct-Axis 13.3 11.6 6.56 7.4 7.2 11.34 10.8
Transient Open
circuit time
constant T’d (Sec)
Direct-Axis 0.27 0.04 0.40 0.04 0.25 1.56 1.62
Transient short
circuit time
constant T′ d (Sec)
Rotor Resistance 0.3638 0.175 0.0508 0.1165 0.226 0.3242 0.3671
(ohm) (at 20 °C) (at 75 °C) (at 20 °C) (at 20 °C) (at 20 °C) (at 20 °C) (at 20 °C)
Stator Resistance 0.00061 0.0011 0.00107 0.00079 0.001 0.00058 0.00053
(ohm) (at 20 °C) (at75 °C) (at 20 °C) (at 20 °C) (at 75 °C) (at 20 °C) (at 20 °C)
Insulation Class F F F F F F F
Excitation system SEMIPOL STATIC ROTA STATIC ROTA SEMIPOL SEMIPOL
(Static) DUCT DUCT (Static) (Static)
(Rotary) (Rotary)
Brushless Brushless
Cold Air Temp °C 55 50 50 33.3 36 40 40

38
S W IT C H G E A R S
220 KV CIRCUIT BREAKERS

Make Nova Magrin Galiloo Italy GEC ALSTHOM SIEMENS
Type SF6 / Air operated SF6 / Hydraulic oil SF6 / Hydraulic oil
operated operated
Rated Voltage 145 KV 145 KV 145 KV
Rated current 2000 Amp 2000 Amp 2000 Amp
Rated breaking 40 (KA) 40 (KA) 40 (KA)
capacity
BIL 1050 KV 1050 KV 1050 KV
No. of circuit 6 18 9
breaker

Make Nova Magrin Galiloo Italy Nova Magrin Galiloo Italy
Type SF6/Air operated SF6/Air operated
Rated Voltage 145 KV 145 KV
Rated current 1600 Amp 3000 Amp
Rated breaking 40 (KA) 40 (KA)
capacity
BIL 650 KV 650 KV
No. of circuit 17 1
breaker
Description Unit 1,2 Unit 3,4 Unit 5-8 Unit 9,10 Unit 11,12 Unit 13,14
Make SIEMENS Nova Magrin Marlin AEG Marlin SIEMENS
Germany Galiloo Italy Gerin Gerin ABB
Type Vacuum Air SF6 Vacuum SF6 Vacuum
Magnetic
Rated Voltage 12 KV 12 KV 12 KV 12 KV 12 KV 12 KV
Rated current 1250 Amp 1250 Amp 1250 Amp 630 Amp 800 Amp
Rated breaking 25 (KA) 25 (KA) 25 (KA) 25 (KA) 25 (KA) 20 (KA)
capacity
No. of circuit 26 24 42 40 36 48
breaker

39
UNIT POWER TRANSFORMERS

Make TRAFO ANSALDO ALSTHOM TOSHIBA ALSTHOM TRAFO TRAFO
UNION UNION UNION
Rated Power MVA 117.6/147 77/95.5 125 90/135 112/125 168 190
Rated Voltage KV 10.5/139 11.139 11.5/240 11/139 11.5 / 11 / 258 11 / 258
(LV/HV) 240.18
Rated Frequency 50 Hz 50 Hz 50 Hz 50 Hz 50 Hz 50 Hz 50 Hz
No of Phases 3 3 3 3 3 3 3
Rated Current (A)
(LV/HV) 8083/611 5012/396 6276/300 7090/561 6276/300 8819/422 8083/661
Connection YNd11 YNd11 YNd11 YNd11 YNd11 YNd11 Ynd11
Symbol
Type of Cooling ONAN/ ONAN/ ONAN/ ONAN/ ONAN/ ONAN/ ONAN/
ONAF ONAF ONAF ONAF ONAF ONAF ONAF
Temp. Rise °C 55/50 55/50 55/50 55/50 55/50 55/50 55/50
Winding/Oil
Type of Tap On Load On Load Off Load On Load Off Load Off Load Off Load
Changer
Total No. of Taps 17 15 09 17 09 11 11
Impedance % 9.2/11.5 10.9 14.5 12.63 14 14 15.5
Connection Star/Delta Star/Delta Star/Delta Star/Delta Star/Delta Star/Delta Star/Delta
(HV/LV)
UNIT AUXILIARY TRANSFORMERS
Make SIEMENS O.T.E ALSTHOM PEL ALSTHOM TRAFO SIEMENS
UNION
Type of cooling ONAN ONAN ONAN ONAN ONAN ONAN ONAN
Rated power 1000 2500 1250 630 630 800KVA 1250
(KVA)
Frequency (Hz) 50 50 50 50 50 50 50
Impedance % 5.47 8.38 5.5 4.09 4.21 % 5.8 % 5.98
Rated voltage KV 11/0.4 11/0.415 11.5/0.4 11/0.4 11/400 11/400 11/0.4
(HV/LV)
Rated current 52.5/ 131.2/ 6.56/1804 33.1/ 33.1/909.3 42/1155 65.6/
(AMP) 1443.4 3478 909.3 1804.2
Vector group DYN11 DYN11 DYN11 DYN11 DYN11 DYN1 DYN11
Total no. of taps 5 5 5 5 5 5 5
Type of tap Off Load Off Load Off Load Off Load Off Load Off Load Off Load
changer
Temp. rise 50/55 55
oil/winding
Connection Delta/Star Delta/Star Delta/Star Delta/Star Delta/Star Delta/Star Delta/Star
(HV/LV) Δ/Ү Δ/Ү Δ/Ү Δ/Ү Δ/Ү Δ/Ү Δ/Ү
Weight of oil KG 1035 1200 5100 600 385 1257

40
GENERATOR EXCITATION TRANSFORMER

Description Unit 1,2 Unit 3,4 Unit 9,10 Unit 13,14 Unit 15
Make SIEMENS STEM- MAY & TRAFO TRAFO
TRENTO CHRISTE UNION UNION
Type of cooling ON ONAN AN AN AN
No. of phases 3 3 3 3 3
Operation Continuous Continuous Continuous Continuous Continuous
Rated power(KVA) 630 450 800 1660 1025
Frequency 50 50 50 50 50
Rated current 33.06/ 23.6/927 42/1499.6 87.1/1229 53.5/845
HV/LV(A) 673.6
Rated voltage 11000/940 11000/280 11000/380 11000/780 11000/700
HV/LV(B)
Type of tap Off Load Off Load Off Load Off Load Off Load
changer
No. of taps 5 5 5 3 3
Vector group YD-5 YD-11 YD-5 YD5 YD-5
Temp. Rise at 50 C
Winding/oil 50/45 50/45 50/45 50 C
Impedance % 5.55 7.0 6.05 5.9 5.8
EXCITATION SYSTEM
Description Unit 1,2 Unit 3,4Unit 5-8 Unit 9,10 Unit 11,12 Unit 13,14 Unit 15
Type STATIC STATIC Rotating STATIC Rotating STATIC STATIC
with Carbon with Carbon Diodes Diodes
Brushes. Brushes
Make AEG Ercole Alsthom MAY & Als AEG AEG
Telefuncon Marelli Christe tho Telefuncon Telefuncon
m
Rated power (kw) 215 115 319 353 293.6 408 366
Rated voltage (V) 342 142 151 236 146 423 423
Rated Current (A) 658 810 2110 1495 2011 946 865
Converters / Blade 6 3 18 3 18 6 6
Duty Continuous Continuous Continuous Continuous Continuous Continuous Continuous
Class of Insulation F F F F F F F
Supply source Auxiliary Auxiliary Auxiliary Auxiliary Auxiliary Auxiliary Auxiliary

41
HEAT RECOVERY STEAM GENERATORS

Description Unit 1,2 Unit 3,4 Unit 11,12 Unit 15
Boiler output (T/H) 208 180.8 96.25 234
Design Gauge Pressure (bar) 62 62 51 60.7
Superheater outlet Pressure (bar) 47.1 48 42 60.7
Superheater Steam Temp. (°C) 505 500 512 530
Heating Surface Area
LP Evaporator (m2) 4345 10200 7439 9914
HP Economizer (m2) 18200 17950 13139 33909
HP Evaporator (m2) 28220 22820 26014 34578
HP Superheater (m2) 5415 3212 9794 5693
Total heating Surface (m2) 56180 54182 56386 84094
REQUIREMENTS OF WATER AT HRSGs

FEED WATER AND WATER FOR SPRAY ATTEMPERATOR
Description Unit
General requirements - Clear and Colorless
Conductivity at 25 °C µS/cm 0.2
PH-Value at 25 °C - 9
Oxygen O2 mg/kg 0.02
Total Iron Fe mg/kg 0.02
Total Copper Cu mg/kg 0.003
Silica SiO2 mg/kg 0.02
Carbon dioxide CO2 mg/kg Not detectable
Hardness mval/kg Not detectable
KMnO4 Consumption mg/kg 5
Oil mg/kg 0.3
BOILER WATER
Description Unit
Conductivity at 25 °C µS/cm 150
PH-Value at 25 °C - 9.5 – 10.5
Silica SiO2 mg/kg 5
Phosphate PO4 mg/kg 61

42
Symbols in System Diagrams

Symbols used in System Diagrams are stipulated in DIN 2481. This standard
provides the full scope of symbols which are used in power plant
engineering. An excerpt of this standard containing most frequently used
symbols in the system diagrams is filed here.
DIN Standard Valve
Symbols
Shut off valve general Shut off through valve
Hand Operated Fitting with constant

setting action
Motor Operated Fitting with safety function
Solenoid Operated Non-return Non-return

valve general through-valve
Fluid Operated
Non-return valve Non-return valve
without spring with spring
Piston Operated
Diaphragm Operated Controlled

non-return valve
Control valve
Throttle valve with Throttle valve
constant restriction adjustable
Angle valve or ball valve
Check valve
Safety shut off

Three way valve Safety relief valve
valve
Coupling general
Four way valve
Separator general
Pressure reducing valve
Gate valve or
Main slide valve Air Filter
Strainer
Ball/cock valve Liquid Filter
3-way cock valve
Cooling Tower general

Butterfly valve

Fitting with constant
setting action
Non-return
43 through-valve
DIN Standards Pumps Compressors
Pump general Compressor general
Centrifugal pump Diaphragm Compressor
Reciprocating pump Rotary vane
Rotary pump Reciprocating
Screw pump Turbo Compressor
Gear pump Liquid ring Compressor
Screw Compressor
Root Compressor
Special Accessories
Orifice
Flow meter Gas Turbine
Inspection glass
Mixing section
Surface heat exchanger Steam Turbine
Ignition gas cylinder

Generator
Burner
Combustion chamber Tank

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Basic Power Plant 4

Gas Turbines Basics 7

Heat Recovery Steam Generator 12

Future Load Expansion 15

There are four types of base load power plants:

o High efficient combined cycle plants fueled by natural gas

There are two major categories of combined cycle systems:

1 Oil or natural gas fired systems for power generation.

2 Combined cycle cogeneration systems and coal or oil fired integrated

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BASIC POWER PLANTS:

Conventional Steam Power plants:

Features of conventional steam power plants are:

They are about 34% efficient in converting fuel to electricity.

With coal costs of $1.35/MMBtu, the fuel cost of producing electricity is

Simple Cycle Peaking Units:

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Basic features of a simple cycle power plant are listed below:

The start up time to full load is approximately 10- 20 minutes.

Combined Cycle Power Plant:

Figure 1 is simple representation of a CCGT system. It demonstrates the fact that a

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ηCC = ηB + ηR - (ηB * ηR) (1)

Utilizing equation (1) would lead to the following conclusion.

ηCC = 0.4 + 0.3 – (0.4 * 0.3)

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Overall efficiency of converting fuel to electricity is greater than a peaking plant

However, a combine cycle plant has a high efficiency in converting fuel to

For natural gas costing $3.50/MMBtu, the fuel costs of producing

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GAS TURBINE BASICS:

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Applications of Gas Turbines:

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The Brayton Cycle:

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Figure 4: Gas Turbine schematic showing relative points

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HEAT RECOVERY STEAM GENERATOR:

Figure 5: Natural Circulation HRSG modular construction Chase.

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Combine-cycle equipment can be and should be adapted to installation requirements

FUTURE LOAD EXPANSION:

Economics of power generation can be improved by installation generation capacity as

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Diverter Damper Description:

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Figure 7: Three-Phase Power for the Diverter Damper Control System.

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Langston, Lee S. University of Colorado, Opdyke, George Jr., Dykewood Enterprises,

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