Major Equipment of Gas

Turbine

Debabrata Das Rana

Executive Engineer
Mechanical maintenance
225 MW CCPP
 Turbines
Machines to Extract Fluid Power from Flowing Fluids

Steam Turbine Water Turbines Wind Turbines Gas Turbines

•High Pressure, High Temperature Gas Aircraft Engines

•Generated Inside the Engine Power Generation
•Expands Through a Specially Designed TURBINE
Gas Turbine and Combined
Cycle Power Plants
 Advantage of Gas Turbine
• Very high power to weight ratio and are lighter and smaller
than internal combustion engines of the same power
• They are small in size, mass, and initial cost per unit output.
• Their delivery time is relatively short and they can be
installed quickly.
• They are quick starting (as low as 10 s), often by remote
control.
• They are smooth running and have a capacity factor (percent
of time the unit is operating at full power) of 96 to 98 percent.
• They can use a wide variety of liquid and gaseous fuels
including gasified coal and synthetic fuels.
• They are subject to fewer environmental restrictions than
other prime movers.
• If Operated in Combined Cycle Mode Better Efficiency than
Any Other Power Generation Technique Except Hydro (Up
to 61%)
 Power Generation Efficiency
• Hydro Plants :85%
• Thermal (Coal) :46%
• Gas Turbine:
• Simple Cycle: 38%

• Combined Cycle: 61% (Latest)

• Solar :
• Voltaic : 15%
• Thermal : 30%
• Wind : 40%
• Nuclear : 35%
• Petrol Engine :20%
• Diesel Engine : 25%
5
Energy distribution in a combined cycle power plant
 Heat Rate
• The conversion efficiency of power plants is often expressed
in terms of heat rate, which is the amount of heat supplied, in
KJ (Kilo Joules), to generate 1 kWh of electricity.
• The smaller the heat rate, the greater the efficiency.
(Considering that 1 kWh = 3600 KJ and disregarding the
losses associated with the conversion of shaft power to
electric power, the relation between the heat rate and the
thermal efficiency can be expressed as:
Efficiency = 3600 (KJ/kWh) / Heat rate (KJ/kWh)
 For example, a heat rate of 11,988 KJ / kWh is equivalent to
30 percent efficiency.
 Shikalbaha: 2521 kcal / Kwhr = 10555KJ (1 Kcal = 4.187 KJ)
 3600 /10555 = 34%
 Changes in efficiency by percentage points (%-points), which
should be distinguished from relative changes in percentage.
 For example, a change of 1%-point in efficiency (from 36%
7 to 37%) represents a relative change of 2.7%.
 Gas Turbine
• A gas turbine, also called a combustion turbine, is a type of
internal combustion engine.
• It has an upstream rotating compressor coupled to a
downstream turbine, and a combustion chamber in between.
• The gas turbine is the heart of the power plant.
• A gas turbine is a combustion engine that can convert natural
gas or other liquid fuels to mechanical energy which then
drives a generator that produces electrical energy or power
output.
• Efficiency approx 40% for gas turbine however in the CCPP
plant the efficiency is 50-60% (even higher for cogenerated
plant)
• Low Green Gas Emission C02, NOx & SOx
• Cheaper comparing to other technology e.g. CCS
• Lifetime 30-40 years
 Combined Cycles Today Practices
• Gas Turbine: Up to 470 MW (Simple Cycle) with 41%
• Combined Cycle: 701 MW (One on One) with 61%
• Other Configurations:
• Up to 701 MW for 1 on 1 configuration (Very Recent)

• up to 750 MW for 3 on 1 configuration

• Up to 520 MW for 2 on 1 configuration

• Plant Efficiency ~ 58-61 percent

• Biggest losses are mechanical input to the compressor

and heat in the exhaust

• Steam Turbine output
• Typically 50% of the gas turbine output

• More with duct-firing

• Construction time about 24 months

• Engineering time 80k to 130k labor hours
9
 Classification
• E class combustion turbines have a firing temperature
up to 2,200F or 1200°C and are considered proven
technology,
• F class combustion turbines have a firing temperature up
to 2,500F or 1370°C and are considered proven
technology,
• G class combustion turbines have a firing temperature
up to 2,700F or 1480°C and are considered proven
technology
• The latest next generation combustion turbines have a
firing temperature up to 2,900F or 1600°C.
• These combustion turbines enter service as prototype
technology, and after the fleet leader accumulates over
8,000 equivalent operating hours without any major
component exchanges due to durability issues, they can
then be classified as proven technology. (Now: H Class)
GE - 9HA gas turbines

14 Stages Compressor
Siemens H- Class

16 Combustor Cans
12 Compressor Stages
 High Efficiency Gas Turbine Models
Power
Manufacturer Model Simple Cycle Combined Cycle Produced
Efficiency Efficiency (simple)
(MW)
Alstom GT24 40 58.4 230.7

Mitsubishi M501J 41 61.5 327

General Electric 7FA 38.5 58.5 216

General Electric LMS100 44 53.8 103

Siemens SGT6-8000H 40 60.75 274

Siemens SGT6-2000E 33.9 51.3 112

Hitachi H-25 34.8 50.3 32

225 MW CCPP, Sikalbaha, Chittagong, Bangladesh

Configuration:
1 x GTG Siemens STG5-2000E,
1 x HRSG,
1 x STG Siemens SST-800

Fuel: Natural Gas & HSD Oil

(Dual Fuel)
Output: 225 MW + 10%

Salient Features:
-Multi Shaft GT,
-HRSG Without Duct Firing
(Unfired)
-Bypass Stack
 Plant Functional Schematic

Air

Air Intake
Shikalbaha
 What is the CCPP / CCGT?
 A combined cycle gas turbine power plant, frequently identified by
CCGT /CCPP (shortcut) 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.

 The gas turbine exhaust is then used to produce steam in

a heat exchanger (steam generator) to supply a steam
turbine whose output provides the means to generate
more electricity.

 However the Steam Turbine is not necessarily, in that

case the plant produce electricity and industrial steam
which can be used for heating or industrial purpose
Simple Cycle / Open Cycle Mode
Gas Turbine Unit
Consist of:
1.) Air Intake System
2.) Compressor and Blow-off
3.) Turbine
4.) Generator
5.) Starting Unit
6.) Shaft and Bearings
7.) Exhaust Stack
8.) Local Control Room
Brayton / Joule Cycle
Open Cycle Arrangement
 Gas Turbine components
• Inlet system:
• Collects and directs air into the gas turbine. Often, an air cleaner
and silencer are part of the inlet system. It is designated for a
minimum pressure drop while maximizing clean airflow into the
gas turbine.
• Compressor:
• Provides compression, and, thus, increases the air density for the
combustion process. The higher the compression ratio, the
higher the total gas turbine efficiency . Low compressor
efficiencies result in high compressor discharge temperatures,
therefore, lower gas turbine output power.
• Combustor:
• Adds heat energy to the airflow. The output power of the gas
turbine is directly proportional to the combustor firing
temperature; i.e., the combustor is designed to increase the air
temperature up to the material limits of the gas turbine while
maintaining a reasonable pressure drop.
 Gas Turbine components
Power Turbine:
Converts the flow energy from the gas into useful shaft output
work.
The higher the temperature difference across the power turbine,
the more shaft output power is available.
Turbine has 3 – 5 Stages to Optimize Efficiency and First (2),
or(3) or (4) Stages Cooled by Air Bled from the Compressor
Stages.
Exhaust System:
Exhaust to discharge the gas After Extracting Work to the stacks
Often a silencer is part of the exhaust system.
Similar to the inlet system, the exhaust system is designed for
minimum pressure losses.
Generator:
Generators are 3-Phase wye Connected 50 Hz Totally Enclosed
Hydrogen Cooled Synchronous Machines Suitably Rated
 Gas Turbine Systems

Air System:
• Air intakes are located high up & multiple filters

Fuel System:
• Uses either Heavy Fuel Oil or Diesel Oil, Natural Gas,
LNG, etc.
Lubrication and Control Oil System:
• Supply bearings and Control gears with oil
 Gas turbine power flow
40Unit

Gas Fuel

100 Unit
 Typical Simple Cycle CT Plant Components
• Air Handling System
• Fuel Supply & Preparation
• Prime Mover (Combustion Turbine)
• Compressor

• Combustor

• Combustion Turbine

• Generator
• Generator Step Up Transformer
• Starting System (Combustion Turbines)
• Electrical Switchgear
• Auxiliary Cooling
• Fire Protection
• Lubrication System
• Emissions Control Equipment
33
Air Intake and Handling System
 Defining ISO Conditions

 Industry practice is to quote Output / Efficiency ratings at

ISO conditions
ISO Conditions:
- Inlet Air 15 deg. C
- Relative Humidity 60%
- GTG Location 0 MSL
- Fuel Natural Gas (Methane)
- Inlet / Exhaust Losses 0” / 0” of water
column
- Machine Condition New & Clean

Source: GT World
 Standard Condition
Shikalbaha:
• The net output and heat rate of the Unit shall be guaranteed

by the contractor at the following conditions:

• Ambient temperature: 95 F (35 C)

• Site elevation : 1.90 m

• Relative humidity : 98%

• Barometric pressure : 1.013bar

• Generation voltage : 15,750 v

• Power -factor --- 0.8

• Frequency – 50 Hz

• These machines have come a long way since 1872 when Dr.
Franz Stolze designed the first true gas turbine engine with a
fuel efficiency of – a mere 4%.
• In contrast, today’s most advanced designs are capable of
achieving 61% efficiency
 Atmospheric Air
Gas Volume
Nitrogen (N2) 780,840 ppmv (78.084%)
Oxygen (O2) 209,460 ppmv (20.946%)
Argon (Ar) 9,340 ppmv (0.9340%)
Carbon dioxide (CO2) 390 ppmv (0.039%)
Neon (Ne) 18.18 ppmv (0.001818%)
Helium (He) 5.24 ppmv (0.000524%)
Methane (CH4) 1.79 ppmv (0.000179%)
Krypton (Kr) 1.14 ppmv (0.000114%)
Hydrogen (H2) 0.55 ppmv (0.000055%)
Nitrous oxide (N2O) 0.3 ppmv (0.00003%)
Carbon monoxide (CO) 0.1 ppmv (0.00001%)
Xenon (Xe) 0.09 ppmv (9×10−6%) (0.000009%)
Ozone (O3) 0.0 to 0.07 ppmv (0 to 7×10−6%)
Nitrogen dioxide (NO2) 0.02 ppmv (2×10−6%) (0.000002%)
Iodine (I2) 0.01 ppmv (1×10−6%) (0.000001%)
Ammonia (NH3) trace
Not included in above dry atmosphere:
~0.40% over full atmosphere, typically 1%-4%
Water vapor (H O)
Multi-Stage Filtration System
Weather Hood on Inlet Filtration System
Compressor
Difference between Fans, Blowers and Compressors

Equipment Specific Ratio Pressure rise

(mmWg)

Fans up to 1.11 1136

Blowers 1.11 to 1.20 1136 –2066

Compressors more than 1.20

 Compressor
• As ambient air flows into the compressor, energy is transferred
from its rotating blades and pressure increase across the compressor is
from 12- to 45-fold to the air.
• The temperature also increases across the compressor as a
result of the compression process.
• The discharge temperature from the compressor is between
345 and 480°C
• Most compressors operate in the range of 75% to 85% efficiency
and Supplies high pressure air for combustion process.
 To minimize the size and weight of the turbine for a given output
power, the output per Kg of airflow should be maximized.
 This is obtained by maximizing the air flow through the turbine
which in turn depends on maximizing the pressure ratio between
the air inlet and exhaust outlet.
 The main factor governing this is the pressure ratio across the
compressor which can be as high as 40:1 in modern gas turbines.
 Compressor

• Radial/centrifugal flow
• Adv: simple design, good

for low compression ratios

(5:1)
• Disadv: Difficult to stage,

less efficient

• Axial flow (reversed multistage

axial flow turbine)
• Good for high compression
ratios (40:1)
• Most commonly used
Compressor Blading
Gas Turbine Fuels
 Combustion Turbine Fuels
• Gas turbines are commonly fuelled with natural gas,
although fuel oil, synthesis gas or other fuels can be
used.

• Conventional Fuels
• Natural Gas

• Liquid Fuel Oil

• Nonconventional Fuels
• Crude Oil

• Refinery Gas

• Propane

• Synthetic Fuels
• Chemical Process

• Physical Process
 Natural Gas Supply

Gas Pressure Reducing Station:

It reduces the natural gas pressure supplied by the Oil Refineries to the gas
pressure required by the Gas Turbine Units . For example: From 70 Bars to 30 Bars.
 Natural Gas composition (Typical Gas)
Components Mol %
Nitrogen 11.5
Carbon Dioxide 6.5
H2S 0.05
Methane CH4 79.44
Ethane C2H6 1.56
Propane C3H8 0.40
Butane C4H10 0.10
Pentane C5H12 0.05
Hexane C6H14 0.21
Specific Gravity 0.687
Dewpoint @15 bar g -17 deg C
Gross Calorific Value 862 btu/scf
Nett Calorific value 777 btu/scf
Gas Treatment Skid 1
Gas Treatment Skid 3
Fuel Oil Treatment Plant
Diesel Fuel Tank
 Diesel Fuel Tank Facility

Consist of the following components:

1.) Diesel Fuel Tank Farm, 2.) Fuel Treatment Facility,
3.) Fuel Forwarding Pumps, 4.) Fuel Pipe Lines
Combustor
 Combustion Chambers
The purpose of the combustor is to increase the energy
stored in the compressor exhaust by raising its temperature
by Burning the Fuel Supplied
• There is significant increase in temperature in the

combustors to between 1200 and 1650°C

• Combustion System Incorporates Dry Low Nox
Combustors
• Where air & fuel are mixed, ignited, and burned

• Spark plugs used to ignite fuel

Types:
• Tubular (silo type).

• Tubo – Annular, can Annular.

• Annular.
 Combustion Chambers

• An annular combustor is a doughnut-shaped, single,

continuous chamber that encircles the turbine in a plane
perpendicular to the air flow.
• Can-annular combustors are similar to annular
combustors, however they incorporate several can
shaped combustion chambers rather than a single
combustion chamber.
• Annular combustors are based on aircraft turbine
technology and are typically used for smaller scale
applications.
• A silo combustor has one or more combustion chambers
mounted external to the gas turbine body.
• Silo combustors are typically larger than annular or can-
annular combustors and are used for larger scale
operations.
SGT5 – 2000E
Combustion Turbine
 Gas Turbine Assembly
Compressor Power
Turbine Turbine
Section Section
Compressor

r
Gas Turbine Assembly
View of Compressor and Gas Turbine
Gas Turbine Assembly