An Introduction to the Combined Cycle Power

Plant in Astoria

NRG Astoria Combined Cycle Power Plant

In 1997, the New York Public Service Commission argued that the energy company
Consolidated Edison (Con Ed) had become too big for the well sake of New Yorkers. Con Eds
success created little competition in New Yorks electrical sector. New Yorkers were left without
any electrical companies to choose among other than Con Ed. It was believed that a lack of
competition would also hinder innovation at Con Ed. The New York Public Service Commission
proposed that Con Ed sell some of its property to introduce a competitive electrical market in
New York. Con Ed agreed and sold various generating station and turbines. On January 27, 1999,
Con Ed sold a power plant, consisting of a 614 Megawatt Gas Turbine, located in Astoria,
Queens, to current owner NRG energy.

What does NRG Do?

The principle function of NRG is generate energy at its power plant. NRG sells the energy it
generates to a Load Serving Entity (LSG). Individuals do not buy electricity from NRG directly.
Instead, individuals buy energy form LSGs which include companies like Con Ed.
How is Electricity priced and bought?
Nearly 45% of New Yorks electricity is secured to LSGs through long term contracts. The price
which LSGs pay for electricity is dependent on the cost to produce electricity and the amount of
electricity demanded. The rest of the electricity is bought through the New York Independent
System Operator (NYISO) Day-Ahead Market (which is regulated by the New York Public
Service Commission) or NYISOs Real-Time Market. At the NYISO, LSGs tell energy
generating companies how much electricity they expect to need for the following day. Based on
this information, energy suppliers such as NRG bid to supply the energy that an LSG needs.
LSGs also bid on purchasing electricity from different suppliers. LSGs buy most of their though
the NYISO Day-Ahead Market. The New York Public Service Commission can assess if a
company has an unfair advantage and make changes to create a fair market. This is what
occurred in 1997 when Con Ed was asked to sell some of its property to make the market more
competitive. Once a LSG purchases electricity from a supplier it then sells it to individuals at
rate proportional to the price it paid.
NRGs Power Plant

NRGs Astoria Power Plant is currently undergoing improvements. Nicknamed The Project,
NRG aims to upgrade its Power plant to a Combined Cycle Gas Turbine Power Plant (CCGT
Power plant). Currently the Astoria Power Plant is a Single Cycle Gas Turbine Power Plant
(SCGT Power Plant).
Generating Electricity (The Basics)
Single Cycle Gas Turbine power plants contain a turbine that generates electricity using fossil fuels.
Despite advancements in Turbine technology, generating electricity is still rather inefficient. A perfectly
efficient turbine will able to convert 100% of the energy in the fossil fuel into electricity (this is actually
impossible and only works in theory). However, SCGT power plant can only covert about 30% of the
energy into electricity, the rest is lost as heat. Power plants that rely of renewable resources are even less
efficient. The solution is the CCGT power plant. CCGT power plant use the energy lost as heat to
generate more electricity. This allows CCGT power plants to have efficiencies upwards of 60%.
Gas Turbines
Both SSGT and CCGT power plants use gas turbines. Gas turbines generate electricity by converting
fossil fuels into mechanical energy through combustion (the process in which fuel, heat and oxygen are
combined to produce energy). This mechanical energy is then used to generate electricity. Gas turbines
are the primary generator of electricity at fossil fuel power plants. They have five main section:
1.
2.
3.
4.
5.

An Inlet section
Compressor
Combustion System
Turbine
Exhaust System

Inlet Section
The Inlet section is usually located near the beginning of the turbine. Its function is to allow a steady flow
of air to enter the turbine for the combustion process. It is necessary that the flow of air be steady,
otherwise the turbine will be unable to produce electricity efficiently. The air intake must also be clean.
Therefore, the inlet section contains a strong filter that is used to remove any foreign objects from the air
intake. If the airflow is not clean, the turbine can erode causing enough damage for it break down. The
Inlet section may have various types of filters that are specifically designed to trap particles of different
sizes. Some filters are designed to only block particles that are smaller than .5mm. , while others are
designed to specifically stop the flow of liquids (such as water) into the turbine.
Compressor
The compressor follows the Inlet section. The compressor uptakes air, compresses it, and then feeds it to
fuel for combustion. Most compressors are axial compressors because they intake air from the same axis
that air is fed to the fuel. The air itself enters the compressor through the Inlet Section. In order to
maximize the energy generated, air first flows through vanes that properly direct all the air to the

compressor. Compressors consist of multiple stages (usually 14). Each stage has the two following
components.
1. A set of rotating blades that act as airfoils
2. A set of stationary blades called stator vanes

The stator vanes act just like the Inlet vanes. The vanes are aerodynamic and direct air towards
the rotating blades to maximize the energy generated. Each stage starts with a set of stator vanes
and is followed by a set of rotating blades. The rotating blades accelerate the air in the turbine as
it enters the next stage. As the air accelerates the impact pressure (pressure that is dependent on
the airs velocity) increases. Each stage is smaller than the previous. As the air goes through each
stage it becomes more compressed. This causes the static pressure (pressure that does not depend
on the airs velocity) to also increase. These increases in pressure cause the air to become
compressed. As gases such as air get compressed their temperature rises. Air within the
compressor can rise to a temperature of 550 degrees Fahrenheit. Once the air has gone through
the multiple stages it passes through exit vanes that direct it towards the Diffuser. The Diffuser
slows down the airs velocity causing the impact pressure to convert to static pressure. This
ultimately helps the turbine be more efficient.
Combustion
Combustion is the process in which fuel and air are mixed at high temperatures to release energy.
Once air leaves the Diffuser it enters the combustor where this process occurs. The combustor
has three main parts:
1. Liner
2. Fuel Injector
3. Igniter
The Liner is where the combustion process occurs. In here fuel, air and heat are mixed starting
the combustion process. The Liner is built to be tough so it can withstand the high temperature
and pressure. The Fuel Injector is the device that sprays fuel into the liner. Fuel injectors contain
a filter at their end so that the fuel is dispersed into tiny droplets, this ultimately speeds up the
combustion process. Combustors also contain igniters which behave like spark plugs. The heat
energy in the Liner may not always be enough for the combustion process. Therefore, an
electrical igniter is often used to increase the amount of energy present. While every combustor
has these components, they may not all have the same layout.
There are three types of combustor layouts:
1. Annular
2. Can
3. Can - Annular
An annular combustor has one Liner. The Liner is shaped like a donut (or annular). Annular
combustors efficiently utilize space and are the most commonly seen layout among combustors.
Can combustors have multiple Liners and are composed of cans. Each can acts as an independent

combustor with its own fuel injector, igniter and air supply. While all the cans are interconnected,
their each receive air from different air ducts. Can Annular combustors are also comprised of
cans. The cans work in conjunction with each other and are oriented in an annular shape. Unlike
the can combustor, cans in the can annular combustor share the same casing and supply of
oxygen.
Turbine
The energy generated through combustion causes the gas to expand. This energy is then used to
drive the turbine. The turbine is quite similar in design to the compressor. Like the compressor,
the turbine contains multiple stages of rotating blades and stationary vanes, though, turbines have
relatively few stages, usually only about four. When the expanding gas is directed to the turbine,
it causes the blades to rotate. The rotational energy draws in more gas to the turbine. More
importantly, the rotational energy is used to drive a shaft. In CCGP, the shaft is used to generate
approximately half of the plants power.
Exhaust
Once the gas passes through the turbine, it leaves as exhaust through a duct. The gas is still
expanding and leaves the turbine with tremendous force. Jet planes use the force generated as
forward thrust. However, the thrust does not provide much use to power plants. Therefore,
turbines at power stations often have diffusers that slow down the gas as it leaves the turbine.
While regular power plants simply view the exhaust as waste, CCGP use the exhaust to generate
nearly 50% of their energy output (see alternator).
CCGT Power Plant
CCGT power plants are called combined cycle power plants because they have two cycles:
The Brayton Cycle and the Rankine Cycle. These cycles work in conjunction with each other to
generate electricity through different processes.
Brayton Cycle
CCGT produce electrify through the use of two cycles. The first cycle is the Brayton Cycle. The
Brayton cycle is the process that occurs in gas turbines (detailed above). It generates work that
turns a shaft. This shaft is connected to a generator that produces electricity. Both CCGT power
plants and SCGT power plants use the Brayton Cycle to generate electricity.
Alternator
Power plants use a specific generator, called an alternator, to generate electricity. All alternators
have three primary components:
1. A shaft
2. A coil

3. A magnet
In an alternator, electric current is generated when a coil experiences a change in magnetic field.
Alternators at power plants consist of a coil surrounded by a magnet generating a magnetic field.
The coil is connected to a rotating shaft. This shaft is the same shaft connected to the gas turbine.
When the coil is not rotating, the magnetic field induces a voltage onto the coil. As the coil
rotates, its orientation with respect to the magnetic field changes. According to Faradays Laws
the induced voltage is proportional to the negative rate of change of the magnetic field (Liao,
10-3). This means that as the orientation of the coil changes, so does the voltage. This change in
orientation ultimately produces current (flow of electrons) in the wire that can be used by
individuals. The current produced is called Alternating Current (AC) because the current changes
direction. This change in direction occurs depending on the orientation of the coil and magnetic
field.

Rankine Cycle
The Rankine cycle is what differentiates CCGT power plants from SCCT power plants. The
Rankine cycle uses heat energy to create mechanical energy that ultimately generates electricity.
This is opposed to the Brayton cycle which uses fossil fuel energy to create mechanical energy.
Like the Brayton cycle, the Rankine cycle is simply the process in which energy is generated.
The cycle can be created through a variety of mechanisms. CCGT plants use a system called the
Heat Recovery Steam Generator (HRSG) to create the Rankine cycle from the heat exhaust of
the gas turbine.

Heat Recovery Steam Generator

The HRSG is the second cycle at CCGT power plants. It uses the wasted heat from the turbine to
create steam. This steam is then fed into the turbine. From here the Brayton cycle occurs to
create electricity. The HRSG is not piece of machinery but rather a system of multiple of
multiple parts. The HRSG includes:
1.
2.
3.
4.

Economizer
Drum
Evaporator
Superheater

Figure: HRSG

These components work as steps that eventually create highly pressurized steam to be used in the
turbine.
Economizer
The economizer is made up of long water tubes usually composed of steal. The economizer heats
up the water in the tubes to a point near its boiling point. Exhaust from the turbine may not
always be enough heat to convert all water in steam. The economizer guarantees that the water
will turn into to steam by providing some of the energy required for the water to evaporate. If not
all of the water turns into steam, parts the HRSG may get flooded. At times the economizer may
cause the water to boil. This means that the economizer may have added more heat than is
needed. This is not a good occurrence as it means that the power plant used more energy than
needed to generate electricity. It also means that net energy output of the power plant will be less.
Drum
Once the water has been heater in the economizer it, and any steam generated, get sent to a steel
drum. The steel drum has three main functions:
1. Storage
2. Separating steam and water
3. Steam purification
While idle, the steel drum simply stores water. However, whenever the drum is in active use its
main function is to separate out any steam and then purify it before it enters the turbine. While it

is not ideal for the Economizer to generate steam, it often does. Depending on the pressure
conditions, 5 to 10% of the drums contents may be steam. The steam must then be separated as
it can be used (unlike the water) by the turbine. Steam is separated by the drum through two
steps:
1. Primary Separation
2. Secondary Separation (also called Steam Scrubbing)
Primary Separation
The primary separation step uses centripetal force to separate the steam from the water. Along
the steel drum are hydrocyclones; a device that separates fluids (air is a fluid) of different
densities. Hydrocyclones having no moving parts, instead they are internally structured such that
substances of different densities are separated out. When water/steam mixture enters the cyclone
there different densities cause them to drift to different areas of the cyclone. The water is forced
against the walls of the cyclone while the air makes its way to the center of the cyclone. The
water (which is now at least 98% free of steam) is then discharged from the bottom cyclone and
goes on to the next component of the HRSG. Separated steam leaves the cyclone by simply
rising above. Afterwards, secondary separation is done to clean the steam.

Figure: Hydrocyclone

Secondary Separation

As the steam rises it comes in contact with a very fine mesh. The mesh is able to remove any
minuscule foreign objects or water partials that exists in steam. The filter water goes onto the rest
of the components in the HRSG while steam goes to the turbine to generate electricity.
Evaporator
The evaporator is where the water gets converted to steam. The evaporator is the same layout as
the economizer. Both the economizer and evaporator consist of steel tubes that heat water.
However, the heat transferred to the water comes from different sources. The heat in the
economizer is generated using electricity. The heat transferred to water in the evaporator is from
the turbines exhaust. At the evaporator all the water is converted to steam. As the water
evaporates, additional water is fed into the evaporator until all the heat energy is used up.
Superheater
Before the generated steam enters the turbine it goes through the Superheater: the last component
of the HRSG. The superheater stores some energy form the turbines exhaust. This heat energy is
used to superheat to the steam generated in the evaporator. When steam is superheated it has
more heat energy than before. Superheated steam is therefore hotter than steam that has not
superheated. The steam is superheated so that it remains in a gaseous state. If the steam was not
superheated it may quickly turn back into water which is useless in a gas turbine.
Steam Turbine
Once the steam goes through a HRSG the steam is fed into a steam turbine. The steam turbine
follows the same principals of a gas turbine (detailed earlier). Steam turbines do not require any
fossil fuels thus they have no use for combustion either. However, both steam and gas turbines
have turbines that are structured the exact same way. Both contain stages with rotating and static
blades. They both also have a shaft. The main difference is that in a gas turbine, energy is
generated from fossil fuels. In a steam turbine, energy is generated from steam.
The Power Grid (In Brief)
The power grid is the entire system set up to transfer electricity. The power plant is just one
component of the power grid. The power grid encompasses everything from electricity
generation to electricity consumption by individuals. The power grid has 7 major components:
1.
2.
3.
4.
5.
6.
7.

The Power Plant

Transmission Substation
Distribution Grid
Distribution Bus
Regulator Bank
Taps
Consumer

Power Plant

The power plant is the first component of the power grid. The power plant generates high voltage
AC that cannot be used in anything. The power plant also generates electricity of three different
phases. Each phase is offset by 120 degrees. The power plant transmits electricity to the
transmission substation though four electric cables. Three of the cable lines hold different phases
while the fourth cable is neutral.
Transmission Substation
Electrical cables are used to transfer electricity efficiently. They have little electrical resistance so
current can flow through with ease. However, like nearly everything that exists, electrical cables
still have some resistance. When an electric current travels long distances along an electrical
cable tremendous amount of energy is still lost. Transmission substations step up the voltage
using a device called a transformer. Transformers can step up voltages, increasing the voltage, or
step down the voltage, decreasing the voltage. When a transformer at the transmission substation
steps up the voltage, the voltage is multiplied. This large increase in voltage lowers the amount
of electricity lost as electricity travels along long electrical cables.
Distribution Grid
At the distribution grid, electricity is stepped down by transformers. The resulting voltage is still
too high to be used by most devices. The main point of the distribution grid is to prime the
current for distribution to homes and business.
Distribution Bus
When electricity reaches the distribution bus it is separate into two different lines. One line goes
into a transformer where it is once again stepped down. The voltage in this line is low enough for
distribution to homes. The second line leaves the distribution bus without being stepped down.
This line will get stepped down by a transformer located farther away. Once it is stepped down
its voltage will be low enough for distribution to homes.
Regulator Bank
Regulator banks are usually connected to power lines. They prevent the voltage from becoming
too high or low.
Taps
Taps are used to convert the three different phases generated by the power plant into a fewer
number of different phases. There taps that convert current in three phases into current of fewer
phases. There are also taps that convert current of two phases into current of one phase. The
current used by everyone is of only one phase.
Consumer

The voltage by now is somewhere around 7200 Volts. The typical outlet provides 240 volts
depending on where you live. In order bring the voltage down a transformer once again steps the
voltage down. The transformer that does this is called a transformer drum and can be seen on
most electrical poles.
NRGs Future
NRG anticipates that The Project will be completed this summer. Opening a CCGT power
plant will make it cheaper for NRG to produce electricity and thus cheaper for individuals to
purchase. Reports by NRG suggest that opening a CCGT power plant will lower emissions into
the air and benefit the economy by adding new jobs.

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