Open Cycle Powe Plant

CCPP PROCESS FLOW DIAGRAM
Boundary of O & M
Operates by BP
88 BAR
11.5/20 KV
#1 HRSG
86 Ton/h
GAS
SUPPLY
BBG &
PGN
#1 GTG
37 MW
Trafo
#1 GT
GAS COMPRESSOR
88 BAR
Operates by MGU
11.5/20 KV
#2 HRSG
86 Ton/h
#2 GTG
37 MW
Trafo
20/130 KV
Switchgear
SwitchYard
PLN
#2 GT
M
11.5/20 KV
ST
STG
50 MW
CONDENSER
FEED WATER PUMP
WATER
SUPPLY
DEMIN PLANT
MAKE UP COOLING TOWER
WATER
Trafo
Legend :
GT
GTG
ST
STG
HRSG
: Gas Turbine
: Gas Turbine Generator
: Steam Turbine
: Steam Turbine Generator
: Heat Recovery Steam Generator
Electrical Line
Gas Fuel Line
Feed Water/Steam Line
Cooling Water Line
Brayton Cycle
(Gas Turbine Open Cycle)
Brayton Cycle
A simple gas turbine consist of a compressor, combustion chamber, and turbine. The
idealized air standard cycle of gas turbine is Brayton cycle.
1 2 Isentropic compression
2 3 Isobaric heat addition
3 4 Isentropic Expansion
4 1 Isobaric heat rejection
Assumption :
Working fluid : ideal gas with constant specific heat
Heat addition and rejection occur on isobaric condition
Compression and expansion occur on isentropic process
P V and T S diagram of Brayton Cycle
Comp.
Work
Shaft
Work
Shaft
Work
Comp.
Work
The gas is compressed from P1 to P2. Then the heat is added to the gas either by
internal combustion or heat exchanger and the temperature rise from T2 to T3.
The hot is gas expanded in turbine to get useful work in the form of shaft
rotation. The pressure is drop from P3 to P4. The exhaust gas reject its heat
either to atmosphere or heat exchanger and the temperature decrease from T 4 to
T1. At this point the cycle is complete.
Note : P1 = P4 and P2 = P3
Gas Turbine Open Cycle

The gas turbine open cycle is a little different from brayton cycle. In gas turbine
simple cycle the gas is not recycled. The heat rejection process occur in
atmosphere and the new air is introduced in the compression process. In the real
cycle the compression/expansion process are not isentropic. The dash line show
the real compression and expansion process. The heat addition and rejection are
not pure isobaric due to pressure drop.
GT open cycle
T s diagram
Gas Turbine Main Components

Turbine
Comp
Turbine
Axial compressor & turbine
Comp
Centrifugal compressor & turbine
Combustion chamber can
Gas Turbine Open Cycle Enhancement

The basic principles to improve open cycle gas turbine performance :
1. Increase Turbine Entry Temperature (TET)
2. Increase Compression Ratio
3. Decrease Inlet Air Temperature
4. Intercooler
5. Reheat
6. Regenerator
7. Cogeneration
1. Increase Turbine Entry Temperature

By increasing the temperature of combustion gas the performance of the gas
turbine will improve. In open cycle if we increase the hot gas temperature, the
thermal efficiency will drop a little but the specific output (MW/kg/s) increase
significantly. In combine cycle case, both thermal efficiency and specific output
will increase (see figure in next page).
However we cant increase this temperature too much due to limitation in
material melting point and high temperature corrosion phenomenon. To overcome
this barrier, several effort developed by experts as follow :
a.Explore better cooling techniques
b.Research on advance material for hot gas path section
(composite alloy technology, single crystal casting, solid state diffusion
bonding)
a.Coating Technology (Thermal Barrier Coating)

a. Design better cooling system for hot gas path section of turbine

b. Advanced material and coating technology
Since 1950, turbine bucket material temperature capability has advanced approximately 850F/472C, approximately 20F/10C per year. The importance of this increase can be appreciated by noting
that an increase of 100F/56C in turbine firing temperature can provide a corresponding increase of 8% to 13% in output and 2% to 4% improvement in simple-cycle efficiency.

Advance coating technology make it possible for gas turbine today work at
temperature 1400 0C. Coating material protect melting and corrosion (oxidation)
of bucket base metal. The Thermal Barrier Coating (TBC) consist of bonding
coat (MCrAlY) and ceramic/oxide (usually zirconia, ZrO 2). This coating combine
with latest cooling technology using steam will give the higher gas temperature
allowed for gas turbine.
2. Increase Pressure Ratio

Basic brayton cycle thermal efficiency depend on pressure ratio of the
compressor. Higher pressure ratio give higher thermal efficiency.
1-
1
(pr)
(k -1)
k
Ideal brayton cycle efficiency vs pressure ratio
2. Increase Pressure Ratio

In real cycle increasing pressure ratio has limitation where the increase of specific work
consumed by the compressor is greater compared to decrease in specific heat consumption.
Influence of pressure ratio to efficiency and

specific output in typical heavy duty turbines
3. Decrease Air Inlet Temperature
Effect of Inlet Temperature

Cold air is denser than hot air and need lower work to compress. Denser air
means more air (mass) flows through the compressor. The turbine output is
proportional to mass flow. The heat rate also decrease with cooler air due to less
work for compression.
Common method for cooling air inlet :
1.Evaporative cooling (extract heat by evaporate water)
- Evaporative cooler media
- Foggers
- Evaporative intercooling (Overspray/overcooling)
2.Inlet chilling (extract heat by heat transfer from atmospheric air to chilling
refrigerant)
- Direct inlet chilling
- Thermal energy storage
Evaporative Cooler Media
Foggers (water droplet > 10 micron)

Overspray or evaporative intercooling achieved by spray more fog than what can
be evaporated by the air. When the air is compressed, its temperature rise. The fog
evaporate and the compressed air cooling down. The total mass flow increase and
the compression work decrease.
Turbine
Compressor
The main drawback of evaporative cooler : maximum temperature decrease

achieved is the difference between dry bulb temperature and wet bulb
temperature. If the ambient air is humid then this method is not feasible anymore.
The only choice to cool the ambient air is using inlet chiller. The basic principle of
inlet chilling is cooling the air using the cooling coil with cooling liquid from
refrigeration cycle (either by mechanical chiller/vapor compression or absorption
chiller).
Comb. chamber
Cooling
liquid inlet
Chiller
Cooling
coil
Exhaust gas
Cooling
liquid outlet
Ambient
air inlet
Cooling coil transfer heat from ambient air to refrigerant inside the tube
Thermal Energy Storage System For Peaking Power Augmentation

In direct chilling the chiller run all the time whether peak or off peak. The cooling
liquid circulate all the time to cool the ambient air. In case the electricity price so
high in the peak hours people prefer using thermal energy storage. During off
peak the chiller make ice and keep that in storage tank. When the peak load the
chill water in the bottom of the tank pumped to cooling coil for cooling the
ambient air.
4. Intercooler
Intercooled Cycle
4. Intercooler
T s diagram for intercooled compression

The ambient air compressed by LP compressor and intercooled before enter
the HP compressor. The work for compression in HP compressor decrease so the
work output and efficiency increase. The intercooler can be either direct contact
(evaporative) or extended surface heat exchanger.
5. Reheat
After leaving the first turbine some fuel added second combustor and give extra
work on second turbine. The exhaust temperature is still high (T 6) therefore
increased the heat potential for regeneration.
6. Regenerator
6. Regenerator
The air from compressor extract heat from exhaust gas so reduce the fuel
consumption. From above T s diagram we can see the heat required to achieve
T3 is divided into two, from T2 to T5 using exhaust gas, and the rest (from T5 to
T3) using heat from fuel combustion.
7. Cogeneration
7. Cogeneration
In cogeneration cycle, the exhaust gas from GT enter the HRSG and the heat
extracted to produce steam. The steam can be used for driving steam turbine,
injected back to gas turbine or for process steam.

Open Cycle Powe Plant

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CCPP PROCESS FLOW DIAGRAM

FEED WATER PUMP

P V and T S diagram of Brayton Cycle

Gas Turbine Open Cycle

Gas Turbine Main Components

Axial compressor & turbine

Centrifugal compressor & turbine

Combustion chamber can

Gas Turbine Open Cycle Enhancement

1. Increase Turbine Entry Temperature

1. Increase Turbine Entry Temperature

1. Increase Turbine Entry Temperature

1. Increase Turbine Entry Temperature

1. Increase Turbine Entry Temperature

2. Increase Pressure Ratio

Ideal brayton cycle efficiency vs pressure ratio

2. Increase Pressure Ratio

Influence of pressure ratio to efficiency and

3. Decrease Air Inlet Temperature

Effect of Inlet Temperature

3. Decrease Air Inlet Temperature

3. Decrease Air Inlet Temperature

Evaporative Cooler Media

3. Decrease Air Inlet Temperature

Foggers (water droplet > 10 micron)

3. Decrease Air Inlet Temperature

The main drawback of evaporative cooler : maximum temperature decrease

3. Decrease Air Inlet Temperature

3. Decrease Air Inlet Temperature

Thermal Energy Storage System For Peaking Power Augmentation

3. Decrease Air Inlet Temperature

T s diagram for intercooled compression

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