Combined Cycle Power Plant Combined Cycle

Operation Power Plant

Operating Behavior

Training Lesson

ALSTOM (Switzerland) Ltd ABCD

 CCPP Combined Cycle Power Plant
ABCD Operation Operation Behavior

We reserve all rights in this document and in the information contained therein.
Reproduction, use or disclosure to third parties without express authority is strictly
forbidden.
Copyright© by ALSTOM (Switzerland) Ltd 2007

This is a training lesson. It provides overall information about the specific system
only.
To understand the operation concept in detail the project specific documents as
defined in the document reference section have to be included together with this
lesson.
All mentioned / attached values and settings are for information only. Typical
values are used to clarify particular subjects. Settings furthermore are subject to
change site specifically during commissioning.
For actual values please refer to the final plant specific
Operation & Maintenance Documentation.

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Table of Contents
Document Reference ........................................................................................................................... 4
Document Reference ........................................................................................................................... 4
Typical Documents ........................................................................................................................... 4
O&M Documentation ....................................................................................................................... 4
Lesson Objectives................................................................................................................................ 5
Operating and Part Load Behavior....................................................................................................... 6
Combined Cycle Off-Design Behavior............................................................................................... 6
Combined Cycle Off-Design Corrections........................................................................................... 7
Ambient Air Conditions .................................................................................................................... 8
Ambient Air Temperature.................................................................................................................. 8
Ambient Air Pressure ...................................................................................................................... 12
Ambient Air Relative Humidity ......................................................................................................... 13
Cooling Media Temperature ........................................................................................................... 14
Electrical Corrections...................................................................................................................... 18
Process Energy ............................................................................................................................... 19
Fuel Type and Quality .................................................................................................................... 19
Part-Load Behavior......................................................................................................................... 20
Combined Cycle Testing Procedures................................................................................................ 27
Exercises CCPP Operating Behavior ................................................................................................... 29
Off-Design Plant Performance ........................................................................................................ 29
Off-Design Plant Performance Prediction ......................................................................................... 30
Summary .......................................................................................................................................... 31
Objectives Review .......................................................................................................................... 31

Table of Figures
Figure 1: Entropy/Temperature Diagram for a Gas Turbine Process at
two Different Ambient Air Temperatures ................................................................................ 9
Figure 2: Relative Efficiency of Gas Turbine, Steam Process and Combined Cycle as a Function of the
Air Temperature at Constant Vacuum.................................................................................. 10
Figure 3: Relative Power Output of Gas Turbine, Steam Turbine and Combined Cycle as a
Function of Air Temperature at Constant Vacuum ................................................................ 11
Figure 4: Relative Power Output of Gas Turbine, Steam Turbine and Combined Cycle
and Relative Air Pressure versus elevation Above Sea Level................................................... 12
Figure 5: Relative Power Output and Efficiency of Gas Turbine and Combined Cycle versus
Relative Humidity at Constant Vacuum ................................................................................ 13
Figure 6: Effect of Condenser Pressure on Steam Turbine Output........................................................ 15
Figure 7: Effect of Vacuum on Combined Cycle Efficiency................................................................... 17
Figure 8: Effect of Frequency on Relative Combined Cycle Output and Efficiency for
Continuous Full Load Operation......................................................................................... 18
Figure 9: Part Load Efficiency of Gas Turbine and Combined-Cycle .................................................... 20
Figure 10: Ratio of Steam Turbine and Gas turbine Output and Live Steam Data of a
Combined Cycle at Part Load ........................................................................................... 22
Figure 11: Flow Diagram of a Dual Pressure Cycle with Gas Turbine Inlet Air Preheating ..................... 24
Figure 12: Part Load Efficiency of Combined Cycle Plant with Four Single Shaft Blocks......................... 26

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Document Reference
Typical Documents

Typical documents clarify the aspects described in this lesson, which may not show
project specific contents, therefore deviations to the specific installation are possible.
All typical documents are referenced in the lesson and clearly identified.

O&M Documentation

O&M Documents are plant specific and form an important part of each training
course. The training material includes the most relevant O&M Documents and
provides a basis for exercises and personal notes, markings, etc. The most relevant
documents for the operation training are as follows:
• P&IDs with legend
• System descriptions
• Operating instructions
• Operating diagrams
• Instrument lists
• Set point lists
• Maintenance instructions

The O&M Documents are separated into:

• System specific documents
• Overall plant specific documents
The system specific documents are attached to each lesson, whereas the overall
plant specific documents can be found in separate sections at the end of the
training manual.

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Lesson Objectives

Upon completion of this lesson, the trainee is able to:

• Explain all variables which influence the output and the efficiency of the GT- ST-
and combined cycled process with graphs such as the Carnot cycle or entropy /
enthalpy diagrams.

• Explain the standard conditions for the plant design and how these values are
measured and calculated if deviations occur during the performance test.

• Summarize the influence of the fuel quality in regard to power output and
efficiency.

• Summarize the effect of part load operation of the combined cycle power plant
and how a plant, utilizing more than one gas turbine in parallel can be
operated more efficiently.

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Operating and Part Load Behavior

Response to the The power plant response to changes in its operating environment is of great
Grid importance to the overall plant economy. The changes are normally imposed by
different ambient conditions and the power demanded by the grid. In order to
maximize the profit for the owner it is necessary to maintain a low cost of electricity
throughout the whole operating range.

Operating One economic component of electricity production is the fuel cost, which depends
Concept on the plant efficiency. The plant-operating concept determines the operating points
which result in the highest efficiencies. Normally base load efficiency makes a
major contribution, and part-load efficiency is considered, as it is always important
for periods of low demand or for plants continuously operating at part-load to
support the grid with spinning reserve.

Combined Cycle Off-Design Behavior

As opposed to the plant design – in which all components of the water/steam cycle
are defined to meet certain design criteria – the performance of a plant under off-
design conditions depends on the operating environment.

Considerations To find the best possible plant for design and off-design conditions, it is important
for Operating to know both the steady state and the dynamic operating behavior of the plant
Behavior throughout the whole operating range. Theoretical calculations of the dynamic
behavior require precise knowledge of all plant components. For that reason, to
predict this behavior, operating experience from similar plants (or sometimes a
simulator) is frequently used, combined with steady-state plant calculations. This is
an accurate approach, because a dynamic response always leads to a steady-state
operating point, if the necessary time factor is considered. Gas turbine calculations
are straightforward since gas turbines are standardized machines and calculation
tools and correction curves are available for different ambient conditions and part-
load points. The water/steam cycle performance is calculated from the
thermodynamic data at the design point. If that design point is known, general
equations such as the Law of Cones (steam turbine) and the heat transfer law
reduce the calculation to a reasonable number of equations without the need to
consider such things as the dimensions and geometry of the components.

(Continued next page)

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Combined Cycle Off-Design Behavior (continued)

Plant Specific Combined cycle steady-state behavior differs significantly from that of a
Differences conventional steam plant. The differences involve mainly the boiler and the
operating mode of the plant. In an HRSG, the heat is transferred mainly by means
of convection, while in a conventional boiler the main mode of heat transfer is
radiation. Additionally, the steam turbine of a combined cycle plant operates most
economically in sliding-pressure mode (i.e., it is run “uncontrolled” and the steam
data are determined by a combination of the gas turbine exhaust gas properties
and the swallowing capacity of the steam turbine). By contrast, a conventional plant
is often operated at a fixed pressure and with a constant live-steam temperature.
That simplifies calculations because the steam pressure and temperature are known
in advance. The steam turbine and the boiler can therefore be considered
independently of one another.

Combined Cycle Off-Design Corrections

Variations in the behavior due to off-design conditions are similar to the influences
in which the conditions for the combined cycle power plant design point are varied.
This is mainly because gas turbines – which account for two-thirds of the power
output at the design point – are standardized machines, and are not redesigned for
specific applications. They respond in the same way, therefore, whether the
variation in conditions is due to a new design point or to an off-design case for the
combined-cycle. The resulting power output and exhaust gas properties to the
HRSG are the same.

The impact on the water/steam cycle is different for off-design and design
corrections, however it influences only one-third of the total power produced.

Consideration of Operating behavior differs from plant to plant depending on the actual design
Plant point. In the following section, some typical variations are shown. These parameters
Parameters should normally be considered when correcting the combined cycle performance
from one set of operating conditions to another (for combined cycle performance
testing).
Plant load
Ambient air conditions (temperature, pressure, relative humidity)
Cooling media temperature (fresh water, cooling tower water, air)
Frequency
Power factor and voltage of the generators
Process energy
Fuel type and quality (heating value)

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Ambient Air Conditions

Standard The gas turbine is a standardized machine, which is used for widely different
Ambient ambient conditions. This is justified economically because a gas turbine that is
Conditions optimized for an air temperature of 150C (590F) does not look significantly different
from one that is designed for 400C (1040F). The costs for developing a new
machine could not be justified. Manufacturers quote gas turbine performances at
ISO ambient conditions of 150C, (590F), 1.013bar, (14.7psia) and 60% relative
humidity. The gas turbine performs differently at different ambient conditions, which
affects the steam process.

Specific Unlike the gas turbine, the steam turbine is usually designed for a specific
Application of application. The exhaust steam section design, for example, depends on the
the Steam condenser pressure at the design point, e.g. the exhaust section that is chosen for a
Turbine condenser pressure of 0.2 bar (5.9”Hg) can no longer function optimally if the
pressure in only 0.045 bar (1.3”Hg). Also, blade path design in a steam turbine
depends on the live-steam pressure, which is not the same for all cycles.

The important main ambient conditions are the air temperature and pressure.
Relative humidity also has a minor influence but becomes more important if the
water for cooling the condenser is recooled in a wet cooling tower. The following
discussion ambient condition are ISO condition

Ambient Air Temperature

Influence of Air The three reasons why the air temperature significantly influences the power output
Temperature and efficiency of the gas turbine are as follows:
Gas turbines always draw in a constant volume flow to the compressor. Increasing
the ambient air temperature reduces the density of the air and thereby reduces the
air mass flow contained in the given volume flow. The air mass flow determines the
gas turbine output at a given turbine inlet temperature, TIT and pressure ratio.
The specific volume of the air increases in proportion to the intake temperature (in
K), increasing the power consumed by the compressor, without a corresponding
increase in the output from the turbine.
As the air temperature rises and the mass flow decreases, the pressure ratio within
the gas turbine is reduced. This is because, as the swallowing capacity of the gas
turbine is given, the law of cones reduces the pressure before the turbine. The same
principle applies inversely to the compressor, but because the turbine is dominant,
the total balance is negative.

(Continued next page)

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Ambient Air Temperature (continued)

3 3´
Temperature

4´
4

2 2´

Lower Air Temperature

Higher Air Temperature

1´ 1-2 and 1´-2´ = Compressor

2-3 and 2´-3´ = Combustion Chamber
3-4 and 3´-4´ = Turbine
1

Entropy
CSXA401835.cdr

Figure 1: Entropy/Temperature Diagram for a Gas Turbine Process at two

Different Ambient Air Temperatures

Figure 1 shows the gas turbine characteristic at two different ambient temperatures
in a temperature/entropy diagram. The exhaust gas temperature is higher as the air
temperature increases because the turbine pressure ratio is reduced while the TIT
remains constant.
The result is a decrease in gas turbine efficiency and output as ambient temperature
rises. However, the effect on the performance of the combined cycle as a whole is
more moderate because a higher exhaust-gas temperature improves the
performance of the steam cycle.

(Continued next page)

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Ambient Air Temperature (continued)

105

104

103

102
Relative Efficiency (%)

101

100

99

98
Gas Turbine
97
Steam Process
Combined Cycle
96

95

94

-15 -10 -5 0 5 10 15 20 25 30 35 40 45

Air Temperature (°C) CSXA401836.cdr

Figure 2: Relative Efficiency of Gas Turbine, Steam Process and Combined Cycle
as a Function of the Air Temperature at Constant Vacuum

Figure 2 shows the relative efficiencies of the gas turbine, steam process, and the
combined cycle plant as a function of the air temperature. In this figure, other
ambient conditions and the condenser pressure remain unchanged. In the diagram
an increase in air temperature has a slightly positive effect on the efficiency of the
combined cycle plant. Since the increased temperature in the gas turbine exhaust
raises the efficiency of the steam process enough to more than compensate for the
reduced efficiency of the gas turbine unit. This behavior is not surprising considering
the Carnot efficiency. The increase in the compressor outlet temperature causes a
slight increase in the average temperature of the heat supplied (TE), as well. Most of
the steam turbine exhaust heat is dissipated in the condenser so the cold
temperature (TA) does not change because the condenser vacuum is constant. The
overall efficiency of the combined cycle plant will increase.

(Continued next page)

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Ambient Air Temperature (continued)

120

115 Gas Turbine

Steam Turbine
Combined Cycle
110
Relative Power Output (%)

105

100

95

90

85

-15 -10 -5 0 5 10 15 20 25 30 35 40 45

Air Temperature (°C)

CSXA401837.cdr

Figure 3: Relative Power Output of Gas Turbine, Steam Turbine and Combined Cycle
as a Function of Air Temperature at Constant Vacuum

Figure 3 shows how the power output of the gas turbine, steam turbine, and
combined cycle decreases with an increase in the air temperature. The effect is less
pronounced for the combined cycle than for the gas turbine alone. The effect on
combined cycle power output is more noticeable than that on the efficiency because
changes in the mass flows of air and exhaust gases are more dominant than
changes in the exhaust gas temperature.

Effect of Ambient • The power output of the combine cycle power plant decreases rapidly with
Air Temperature higher ambient Temperature.
• The efficiency of the combine cycle power plant is influenced only little by the
ambient Temperature.

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Ambient Air Pressure

Effect of the The main factor influencing ambient pressure is the site elevation. This is purely a
Ambient Air design issue. For a given power plant, the daily weather variations are the only
Pressure cause of change in the ambient pressure. The correction only affects plant output
while the efficiency remains constant.

100 100
GT, ST, Combined Cycle
Air Pressure
95 95
Relative Power Output (%)

Relative Air Pressure (%)

90 90

85 85

80 80

75 75

70 70

0 400 800 1200 1600 2000 2400

Elevation Above Sea Level (m)

CSXA401838.cdr

Figure 4: Relative Power Output of Gas Turbine, Steam Turbine and Combined Cycle and Relative Air
Pressure versus elevation Above Sea Level

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Ambient Air Relative Humidity

Figure 5 shows that gas turbine and combined cycle output increases if the relative
humidity of the ambient air increases with other conditions remaining constant. This
is because at higher humidity levels, there is a higher water content in the working
medium of the gas cycle resulting in a better gas turbine enthalpy drop and more
exhaust gas energy entering the HRSG.

100.50
Relative Power Output and Efficiency (%)

100.00

99.50

Power Output
Efficiency

99.00

10 20 30 40 50 60 70 80 90 100

Relative Humidity (%)

CSXA401839.cdr

Figure 5: Relative Power Output and Efficiency of Gas Turbine and Combined Cycle versus Relative
Humidity at Constant Vacuum

Effect of the An increase in relative humidity increases the enthalpy of the working media of the
Ambient Air cycle. It gives more energy to the HRSG than at the design point, causing slightly
Relative higher energy transfer through the HRSG sections. This leads to a marginal increase
Humidity in the terminal point temperature differences of the HRSG in order to transfer this
additional energy, giving a slight negative tendency for off design calculations.

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Cooling Media Temperature

Carrying off To condense the steam, a cooling medium must carry off waste heat from the
Waste Heat condenser. Generally this is water, which has a high specific thermal capacity and
good heat-transfer properties. Where water is available, cooling is accomplished in
a direct system (using water drawn from a river of the sea) or in a wet-cooling
tower. Where water is not available, very expensive, or to facilitate permitting, an
air-cooled condenser is used. These are expensive items that require a lot of
auxiliary power and operate at a poorer vacuum than the water-cooled options.

The cooling medium temperature has a major effect on the thermal process
efficiency. The lower this temperature is, the higher the efficiency that can be
attained because the pressure in the condenser is lower, producing a greater useful
enthalpy drop in the steam turbine and hence an increase in steam turbine output.
This is illustrated in Figure 6.

The trend is similar for single-, dual-, and triple-pressure cycles. This effect is much
less significant above 100mbar (3.0”Hg) as the relative change in the pressure
decreases and there is less impact on the steam-turbine enthalpy drop. However, at
higher condensation pressure (smaller specific volume) the condenser and the low-
pressure turbine become smaller, less expensive.

(Continued next page)

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Cooling Media Temperature (continued)

110

105
Steam Turbine Output (MW)

100

95

Triple Pressure Reheat

90
Single Pressure
Dual Pressure

85

80

20 40 60 80 100 120 140 160 180

Condenser Pressure (mbar) CSXA401840.cdr

Figure 6: Effect of Condenser Pressure on Steam Turbine Output

(Continued next page)

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Cooling Media Temperature (continued)

Effect of the A change in cooling water temperature affects the volume flow of the steam turbine
Cooling Water exhaust steam. The steam turbine exhaust area is selected at the design point. Away
Temperature from this point the exhaust steam volume flow is different. This increases the
exhaust losses when the cooling water temperature falls so the benefit due to a
better condenser vacuum is reduced. If the cooling water temperature is higher, the
condenser pressure increases, thereby reducing the steam turbine output. The
operating behavior is thus quite different from that which would arise if the size of
the turbine were in all cases adapted to the temperature of the cooling water.

Figure 7 shows the effect of the steam turbine backpressure on the relative efficiency
of the combined cycle plant for a typical direct cooling and a wet-cooling tower
application. It is a plant-specific curve based on a given steam turbine with a fixed
exhaust area that was designed at a certain vacuum. The curve is therefore only
generally applicable for plants with the identical design conditions.

(Continued next page)

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Cooling Media Temperature (continued)

101
Typical Direct Cooling
Typical Wet Cooling Tower

100
Relative Efficiency, %

99

99

98

97
20 30 40 50 60 70 80 90

Vacuum Back Pressure (mbar)

Direct Cooling Design Case Vacuum = 45 mbar

Wet Cooling Tower Design Case Vacuum = 65 mbar
CSXA401829.cdr

Figure 7: Effect of Vacuum on Combined Cycle Efficiency

For part-load conditions, less steam is produced in the HRSG, reducing the amount
of steam leaving the steam turbine exhaust to the condenser. If the cooling water
flow is maintained for full as well as part loads, the vacuum is reduced even further
for part loads. Due to the lower heating of the cooling media and the smaller
terminal point temperature difference of the condenser.

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Electrical Corrections

Frequency The grid frequency has a major impact on plant behavior, as it determines
generator speed and therefore gas turbine speed. The gas turbine compressors
speed defines the airflow entering the gas turbine, which is significant for plant
performance. Gas turbines are normally designed to operate at nominal firing
temperatures for frequencies from 47.5 to 52.5 Hz for a 50-Hz grid, and 57 to 63
for a 60-Hz grid. The same design criteria are valid for steam turbines.

Figure 8 shows a typical variation of combined cycle output and efficiency for
frequency variations. The output decreases for falling frequencies and the efficiency
stays within a narrow range of the nominal frequency point.

101
Relative Combined Cycle Output and Efficiency (%)

100

99

98

97

96

95
Relative Efficiency
Relative Power Output
94

93
47.5 48.0 48.5 49.0 49.5 50 50.5 51.0 51.5 52.5
Frequency (Hz)
CSXA401830.cdr

Figure 8: Effect of Frequency on Relative Combined Cycle Output and Efficiency for Continuous Full
Load Operation

(Continued next page)

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Electrical Corrections (continued)

Power Factor Plant power factors are dictated by the grid and influence the maximum generator
capability and the generator efficiency, which in turn affects the output at the
generator terminals. A normal power factor is in the range of 0.85 to 0.95. At the
nominal point of the generator, a change in power factor from 0.8 to 1 at full load
improves the generator efficiency by 0.3 to 0.4%. For lower loads of the generator
the difference tends asymptotically towards zero.

Process Energy

Plants with process extractions are often highly customized and general off-
designed behavior cannot be given. Process energy has a major effect on plant
performance, making a plant-specific curve necessary.

Fuel Type and Quality

Effect of Back up The main off-design influence of the fuel on cycle performance occurs when a
Fuel back-up fuel is fired (e.g., oil in place of natural gas). The reason for this lies in the
fuel composition and possibly the need for water or steam injection to meet local
emission requirements.
Variations in the composition for the same type of fuel also influence plant
performance because a different fuel composition gives a different chemical
composition after combustion.

Fuel components also determine the lower heating value (LHV) of the fuel. The gas
turbine fuel flow is the heat input to the gas turbine divided by the LHV. If the LHV
decreases, the fuel mass flow increases to provide the same heat input to the gas
turbine. This in turn results in increased flow through the gas turbine, which has a
positive impact on output. However, if the chemical impact of the combustion
products drag the performance in the opposite direction to the LHV influence, the
total influence could be different.

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Part-Load Behavior

In combined cycles without supplementary firing, efficiency depends mainly on the

gas turbine efficiency, the load of the gas turbine exhaust gas temperature and
plant size. So far, all of the corrections discussed have been related to a plant
performance with the gas turbines running at full load with nominal firing
temperature.

Figure 9 shows the part-load efficiency of a combined cycle plant and the
associated gas turbine, each relative to the 100% load ease. At higher loads the
part-load efficiency is good but this drops off more quickly below about 50% for two
reasons.

100

95

90
Relative Efficiency (%)

85

80

75

70

Combined Cycle
65 GT

60

30 40 50 60 70 80 90 100

Load (%) CSXA401831.cdr

Figure 9: Part Load Efficiency of Gas Turbine and Combined-Cycle

(Continued next page)

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Part-Load Behavior (continued)

VIGV First, the gas turbine used is equipped with three rows of compressor-variable inlet
guide vanes, giving excellent part-load efficiency down to approximately 60% load.
This because a high exhaust gas temperature can be maintained as the mass flow
is reduced. Below that level, the inlet temperature must be further reduced.

Sliding Pressure Second, the steam turbine is calculated with sliding pressure mode down to 50%
/ Constant load, also providing good utilization of the exhaust gas in this range. Below that
Pressure point, the live-steam pressure is held constant by means of the steam turbine inlet
valves, resulting in throttling losses.

Output For full-load operation, the gas turbine accounts for two-thirds of the power output
Contribution and the steam turbine for one third. Figure 10 shows how the ratio of steam turbine
GT/ST to gas turbine power output (PST/PGT) shifts towards more steam turbine output at
part loads. At 20% combined cycle load, this ratio is actually reversed, with the
steam turbine contributing two-thirds of the power output and the gas turbine, one-
third.

(Continued next page)

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Part-Load Behavior (continued)

160 600

TLS

140

550
Ratio of ST Output to GT Output, PST/PGT (%)
Relative Live Steam Pressure, PLS/PLSO (%)

120

Live Steam Temperature TLS (°C)

PST/PGT

100 500
PLS/PLSO

80

450

60

40 400

20 30 40 50 60 70 80 90 100

Combined-Cycle Load (%)

CSXA401832.cdr

Figure 10: Ratio of Steam Turbine and Gas turbine Output and Live Steam Data of a Combined Cycle
at Part Load

(Continued next page)

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Part-Load Behavior (continued)

Additionally, the live-steam temperature and relative live-steam pressure of the

water/steam cycle are shown. The live-steam temperature is kept constant by means
of attemperation at the outlet of the HRSG superheater. The reason for the flat
temperature profile lies in the variable inlet-guide vane control, which allows the
gas turbine to operate at a lower flow with the nominal TIT, giving a higher exhaust
gas temperature due to the lower pressure ratio of the unit. The live-steam pressure
drops down to 50% of the full load live-steam pressure and is then controlled by the
steam turbine valves.

There are several-site specific possibilities for further part-load efficiency

improvements, such as:
• Air preheating for sites with cold ambient air temperatures
• several gas turbines in the plant configuration

(Continued next page)

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Part-Load Behavior (continued)

LP

HP

Natural Gas
4 G

1
G

6 5

1 Gas Turbine 4 Steam Turbine

2 HRSG 5 Condenser
3 Feedwater Tank/ Deaerator 6 Gas Turbine Air Preheater
CSXA 401833.cdr

Figure 11: Flow Diagram of a Dual Pressure Cycle with Gas Turbine Inlet Air Preheating

Figure 11 shows an example in which air is preheated using low-pressure steam

from an HRSG allowing a higher relative gas turbine load. For gas turbines with
VIGVs, there is practically no gain at part loads in incorporating this system.

(Continued next page)

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Part-Load Behavior (continued)

Gas Turbines It is an interesting alternative for older gas turbines that have fewer or no VIGVs,
without VIGV however, as it would allow the plant to operate at practically the same part-load
efficiencies as for plants with VIGVs. Normally, the air can only be heated to
approximately 40 to 500C (104 to 1220F) without exceeding the limit imposed by
compressor surge and the last-stage blade temperature limitation, meaning the
efficiency gain drops off at hot ambient temperatures. Sometimes the system is
utilized for modern gas turbines, not to achieve better part-load efficiency, but to
maintain better emissions at lower loads.

Reducing of A combined cycle plant with several gas turbines is operated differently at part-
CCPP Load load. For a plant with four gas turbines and one steam turbine, the overall plant
load is reduced as follows:
• down to 75%, there is a parallel reduction in load on all four gas turbines
• at 75% one gas turbine is shot down
• down to 50%, there is a parallel reduction in load on the three remaining gas
turbines
• at 50%, a second gas turbine is shut down
• etc.

(Continued next page)

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Part-Load Behavior (continued)

1GT 2GTs 3GTs 4GTs

100

95

90
Relative Efficiency (%)

85

80

75

70

65
20 40 60 80 100

Combined Cycle Load (%)

CSXA401834.cdr

Figure 12: Part Load Efficiency of Combined Cycle Plant with Four Single Shaft Blocks

With this mode of operation, the efficiency at 75%, 50% and 25% load is lower than
at full load. If, however, four independent single-shaft combined cycle blocks are
selected, the part-load efficiencies are as shown in Figure 12. In that case, the full
load efficiency would be achieved at the points 100%, 75%, 50% and 25% load
because at these points the individual steam turbines are also running at full load.

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Combined Cycle Testing Procedures

Performance When a power plant is sold, plant performance guarantees are given. These
Parameters guarantees apply to a set of performance parameters and ambient conditions that
cannot normally be recreated for the performance test. This means that, in order to
demonstrate that the guarantees have been met, plant performance must be
measured under the current site conditions and the results must be corrected for the
parameters described earlier. This corrected value is then compared to the
guaranteed values.

In a combined cycle plant the gas turbine, HRSG, and steam turbine all interact with
one another. If the contract for the plant goes to a single general contractor on a
turnkey basis, the power output and efficiency of the plant as a whole can be
guaranteed. Similarly, for combined cycle plants, it is easier to measure the values
for overall plant performance than those for each major component individually.
The amount of waste heat supplied to the HRSG by the gas turbine, in particular,
cannot be measured accurately. When overall values are guaranteed, the fuel flow,
electrical output, and ambient conditions of the power plant must be measured.
These are quantities that can be determined with relative exactness.

Correction Factor Thereafter, a correction factor is determined for each parameter, quantifying its
influence on actual performance due to the fact that each parameter is not at the
design/guarantee value. These correction factors are multiplied together to give
values which can be directly compared to the guarantees.

The power output of the gas turbine and the steam turbine are often corrected
separately.
• For the gas turbine, the usual correction curves take into account the effects
produced by air temperature, air pressure, rotational speed, etc.
• The power output measured for the steam turbine is corrected using curves that
show the indirect effects of air temperature, air pressure, and gas turbine speed
on the steam process and the direct effect of the cooling water temperature.

Computer Model To calculate these curves, it is best to use a computer model that simulates the
steam process as a whole (as described previously in this chapter). Changes in
ambient air data produce changes in the gas turbine exhaust data and these affect
the power output of the steam turbine.

(Continued next page)

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Combined Cycle Testing Procedures (continued)

The advantage of this procedure is that it can, with certain modifications, be used
even if the gas turbine is put into operation at a somewhat earlier date than the
steam turbine. The method is, however, rather complicated and requires quite a few
corrections to cover the interactions between the gas turbine(s) and steam turbine.
Therefore – especially for single-shaft combined-cycles and for plants without
phased construction – there is a trend towards overall combined cycle corrections.

Performance At times, performance predictions after a certain number of operating hours or

Predictions years of operation are required. After commissioning, the plant is normally said to
be in “new and clean condition”. For operating hours beyond this point,
degradation is considered in predicting the performance. The degradation is mainly
caused by the gas turbine and partially recuperated in the steam process.

For steam turbine power plants and for gas turbine and combined cycle power
plants, the methods used for corrections are described in international standards
(e.g., ASME and ISO).

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Exercises CCPP Operating Behavior

Off-Design Plant Performance

Exercise Task Estimate your plant performance for the following, different ambient air conditions:
• Ambient air temperature 10°C lower than guarantee condition.
• Ambient air pressure 5 mbar lower than guarantee condition.

Use the approximate correction curves in your training lesson to estimate the power
output and efficiency your plant will reach under theses off-design conditions.

Note on how to use plant specific correction curves:

• They are applicable for base load and specified fuel only.
• Correction curves correct off-design conditions back to guarantee conditions. So
with this exercise use the curves to correct design conditions to off-design
conditions. Beware of using the relative correction factor properly (adding to or
subtracting from design value).

Exercise Aids • Guarantee Heat balance

• Specific plant correction curves (if available)

Group, • Group work with max. 4 trainees per group

Time Frame, • 20 minutes
Presentation
• Group presentation in front of class

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Off-Design Plant Performance Prediction

Exercise Task 1 Calculate your plant performance for today plus 4 days in advance, based on
weather forecasts for the following conditions:
• Plant on base load;
• Power output and efficiency;
• Midnight low and midday hot conditions.

Exercise Task 2 Draw a power output profile for 24h for your predicted output. If you were to
guarantee your load profile, where are the risks?

Note:
• Be careful about the weather forecasts! How much may the ambient air
temperatures differ from the forecast? Up is bad down is good! Where is your
safety margin?
• Where are your plant risks in regard to power output?
• It’s all about taking controllable risks versus loosing too much economically
(penalties for not meeting a agreed upon load profile).

Exercise Aids • Guarantee Heat balance

• Specific plant correction curves
• Weather report with forecast (newspaper, internet weather channel)

Group, • Group work with max. 4 trainees per group

Time Frame, • 30 minutes
Presentation
• Group presentation in front of class

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Summary
Objectives Review

Carefully review the objectives stated on page 5 of this lesson together with the Test
Questions for Verification of Learning Progress. Note that this lesson is not complete
without the system specific and overall plant Operation & Maintenance
Documentation.

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