s

C 241

Technology Course

Overview to Design and Operation of the

Siemens Combined Cycle Power Plant (CCPP)

TD No. 01

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TABLE OF CONTENT
0 ABBREVIATIONS......................................................................................0-1
1 INTRODUCTION .......................................................................................... 1-1
1.1 Why Combined Cycle Power Plant (CCPP)?................................................ 1-2
1.2 Efficiency of a Combined Cycle Power Plant................................................ 1-4
1.3 Typical CCPP Arrangement.......................................................................... 1-6
2 GAS TURBINE PLANT................................................................................. 2-1
2.1 The Joule-Brayton Process of the Gas Turbine............................................ 2-2
2.2 Main Components of the Gas Turbine.......................................................... 2-3
2.3 Siemens GT-Series ...................................................................................... 2-4
3 HEAT RECOVERY STEAM GENERATOR (HRSG) .................................... 3-1
3.1 The Steam Generation Process ................................................................... 3-2
3.2 General Design............................................................................................. 3-3
3.3 Triple Pressure Reheat Steam Cycle............................................................ 3-4
3.4 Heat Transfer Diagram of the HRSG ............................................................ 3-5
3.5 HRSG Arrangement...................................................................................... 3-6
4 WATER STEAM CYCLE .............................................................................. 4-1
4.1 Water Steam Cycle of a Single Shaft Arrangement...................................... 4-2
4.2 Water Steam Cycle of a Multi Shaft Arrangement ........................................ 4-3
5 STEAM TURBOSET..................................................................................... 5-1
5.1 Main Parameters at a Steam Turbine........................................................... 5-2
5.2 Siemens Steam Turbine Series .................................................................... 5-3
5.3 Main Components of the Siemens Steam Turbines ..................................... 5-4
5.3.1 Siemens Steam Turbine E-Series ................................................................ 5-4
5.3.2 Siemens Steam Turbine DN-Series.............................................................. 5-4
5.3.3 Siemens Steam Turbine KN-Series.............................................................. 5-5
5.3.4 Siemens Steam Turbine HE-Series.............................................................. 5-6
6 SINGLE LINE DIAGRAM AND GENERATOR.............................................. 6-1
6.1 General ......................................................................................................... 6-2
6.2 Electrical Plant .............................................................................................. 6-3
6.2.1 Power Operation........................................................................................... 6-3
6.2.2 Start-up Operation and Standby Power Supply ............................................ 6-4
6.2.3 Emergency Electrical Supply ........................................................................ 6-5
6.3 Generator...................................................................................................... 6-6
6.3.1 General features ........................................................................................... 6-6
6.3.2 Siemens Generator Series ........................................................................... 6-6
6.4 Static Frequency Converter .......................................................................... 6-7
6.5 Static Excitation Equipment .......................................................................... 6-7
7 I & C CONCEPT ........................................................................................... 7-1
7.1 Structure of the TELEPERM XP ................................................................... 7-2
7.2 Task of the TELEPERM XP.......................................................................... 7-3
7.3 SIMADYN D.................................................................................................. 7-4
8 PLANT SYSTEMS COOPERATION............................................................. 8-1

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8.1 Principal / Ancillary Systems and Their Control ............................................ 8-2
8.2 Starting up the Unit / Operation .................................................................... 8-3
9 LIST OF FIGURES ....................................................................................... 9-1

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LIST OF ABBREVIATIONS

AC Alternating current
AS Automation system
AVR Automatic voltage regulator
CCP Condensate circulating pumps
CCPP Combined cycle power plant
CPH Condensate preheater
CT Commissioning tool
DC Direct current
DS Diagnostic system
Eco Economizer
ES Engineering system
FW-CV Feedwater control valve
G Generator
GT Gas turbine
HP High pressure
HRSG Heat recovery steam generator
HV High voltage
I&C Instrumentation and control
IP Intermediate pressure
LAN Local area network
LP Low pressure
LV Low voltage
MV Medium voltage
OM Operating & Monitoring
OM Operating and monitoring
P Pressure
PCC Power control center
RH Reheat(er)
S Entropy
SEE Static excitation equipment
SFC Static frequency converter
SH Superheater
ST Steam turbine
T Temperature
UPS Uninterruptible power supply

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1 INTRODUCTION

TRAINING OBJECTIVES

After the chapter 1 “Introduction” has been dealt with, the trainee should be able to:
• name the main components and the related processes of a CCPP
• name the main reasons why a power plant should have a high efficiency
• give the efficiency of a simple cycle gas turbine power plant
• give the efficiency of a combined cycle power plant
• give the ratio of power of the steam turbine to the total power in a CCPP
• describe the main processes in a gas turbine
• give the ratio of the work consumed in the compressor to the total work produced by
the gas turbine
• describe the main steps of the combined cycle process
• name the main losses of a CCPP
• identify the main components of a single shaft CCPP

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1.1 Why Combined Cycle Power Plant (CCPP)?

Fig. 1.6
The combined cycle power plant CCPP converts the energy contained within the fuel
into electrical energy.
The fuel is burned in the gas turbine and part of the fuel energy is thereby converted into
mechanical energy which then is converted into electrical energy in the generator. The
remaining energy contained in the hot exhaust gas of the gas turbine is partly used to
produce steam in the heat recovery steam generator.
The heat energy of the steam is partly converted to mechanical energy in the steam
turbine and partly released to the environment via the cooling water in the condenser
thereby condensing the steam of the steam turbine. The mechanical energy produced in
the steam turbine again is converted into electrical energy in the generator.
In order to find an answer to the question “Why CCCP?”, the total costs for running a
power plant have to be considered. These costs can be broken down to fixed and
operating costs.
Fixed costs include direct costs which are made up of items such as the costs of
equipment and materials, installation, general construction etc. and indirect costs such
as equipment testing, start up costs, miscellaneous construction expenses and
engineering services etc.
Operating costs (also called variable costs and expenses) are those costs that vary with
the level of output. For power plants, operating costs include fuel costs and variable
operation and maintenance costs. Approximately 60% of a utility’s total revenue
requirements are needed to offset operating costs; fuel is usually the largest single
component.
Therefore fuel saving is the predominant factor for cost saving (at constant power
output), with other words: power plant efficiency is the most important factor.
The CCPP concept is the answer to the challenge to increase the power plant efficiency.

Fig. 1.1
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A simple example shows, how the power plant efficiency can be increased thus saving
fuel costs:
• One could increase the power of a plant with 2 gas turbines by 50% by adding a 3rd
gas turbine, thus increasing the fuel costs by 50% too.
• Alternatively one could use the high heat content of the exhaust gas of the 2 gas
turbines to produce steam in the heat recovery steam generator (HRSG) for the
production of the corresponding power in a steam turbine, thus avoiding the increase
of fuel costs.
The open gas turbine process – also called simple cycle configuration - has a poor
efficiency of about 38% due to the relative high exhaust gas temperature, whereas the
combined cycle configuration reaches an efficiency of up to 60% using the heat content
of the exhaust gas.
As the temperature level of the steam in the steam turbine is lower than the level of the
gas in the gas turbine, the steam cycle is often called bottoming steam cycle.
Typically the steam turbine produces 1/3 of the total power of a combined cycle power
plant.

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1.2 Efficiency of a Combined Cycle Power Plant

Fig. 1.2

When the gas turbine is started, ambient air is drawn through the inlet air system and
then directed to the compressor. The air is compressed by the compressor and directed
to the combustion system. Inside the combustion system, the air is mixed with the fuel
and the mixture is ignited. The compressed and heated combustion gas then flows to the
turbine. The combustion gas expands as it flows through the turbine, causing it to rotate.
The rotating turbine drives the compressor and accessory equipment with available
excess energy to produce shaft power which drives the generator. Approximately ½ of
the work produced is available to produce electricity; the other half is used to drive the
compressor. The function of the generator is to convert mechanical energy of the turbine
into electrical energy.
The gas driving the turbine is exhausted to the atmosphere in the case of the simple
cycle gas turbine process at a temperature of about 500 – 600 °C.

Fig. 1.3, Fig. 1.6

In the case of a combined cycle power plant the exhaust gas from the gas turbine is
directed through a heat recovery steam generator that generates steam at one or more
pressure levels. The steam is fed to a steam turbine that drives a separate generator
(multishaft arrangement). With this arrangement the gas turbine can be decoupled from
the operation of the steam turbine, allowing for steam turbine shutdown with continued
gas turbine operation.
Another configuration is to install one gas turbine, one steam turbine, and one generator
using a single shaft (single shaft arrangement). The steam turbine can be decoupled
from the generator through a clutch. This arrangement can be lower in capital cost
because one generator and a transformer is eliminated.
The exhaust steam is directed to the condenser where it is condensed by transfer of the
condensation energy to the cooling water system. The condensate is fed back to the
heat recovery steam generator and evaporated again – thus closing the cycle.

Fig. 1.4

The combined cycle reaches up to 60% efficiency compared to 38% for the simple gas
turbine process. Nearly 90% of the losses of a CCPP stem from condenser losses,
whereas the stack losses are very low – contrary to the simple cycle process.

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Fig. 1.5

The production of two usable forms of energy – typically electricity and heat – is called
cogeneration. The heat energy is usually recovered waste heat that is used in some
manufacturing process or as heat for building or process heating. The recovery of waste
heat displaces energy that would have been required from a conventional heat source.
When cogeneration is used with combined cycles, about 70% of the energy contained in
the fuel can be used.

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1.3 Typical CCPP Arrangement

Fig. 1.7, Fig. 1.8

Typically the generator is located between the gas turbine and the steam turbine. The
exhaust gas from the gas turbine is released to the atmosphere via the stack after having
produced the steam for the steam turbine within the HRSG. The pressure of the exhaust
gas is reduced to ambient conditions within the diffuser.
Water is fed from the boiler drums on top of the HRSG building through downcomers and
feeders to the inlet headers of the evaporators where water evaporates and the
water/steam mixture is fed via natural circulation in riser tubes from the outlet headers
back to the drums.
After having passed the steam turbine, the steam is condensed in the condenser and
routed back to the HRSG by the condenser pump.
From the generator the electric current is conducted to the transformer via the generator
phase bus.

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2 GAS TURBINE PLANT

TRAINING OBJECTIVES

After the chapter 2 “Gas Turbine Plant” has been dealt with, the trainee should be able
to:
• describe the 4 main stages of the Joule-Brayton process for the gas turbine
• explain the gas turbine performance in the T-S-Diagram
• name the main components of the gas turbine
• classify the different Siemens GT-Series according to their speed and the type of
combustion chamber
• give the power of the different Siemens GT-Series

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2.1 The Joule-Brayton Process of the Gas Turbine

Fig. 2.1

The gas turbine is the machine which converts the chemical energy of the fuel into heat
and part of the heat into mechanical (rotational) energy. Compared to a “normal” fossil
fired steam power station, at a CCPP the gas turbine acts as a combination of both the
furnace and the turbine, since it delivers mechanical work to the generator and thermal
energy via the hot exhaust gas to be used for steam generation.

Fig. 2.2

The gas turbine consists of a compressor section, combustor and turbine section.
Ambient air is first compressed from 1 to 2 . During this process the pressure (and
temperature) of the air is increased, whereas the entropy remains constant as no heat is
added or removed.
Fuel is put into and combusted in the combustor, increasing thereby both the
temperature and the entropy of the medium, but the pressure remains constant. The flue
gas exit the combustor at 3 and expand to 4 in the turbine section. During the
expansion process the pressure (and temperature) of the air decreases, whereas again
as in the compression stage the entropy remains constant.
In a simple cycle process the heat of the expanded - but still hot - flue gas is released to
the atmosphere from 4 back to 1 . During this process both the temperature and
entropy decrease (at constant pressure of the ambient).
The area below the line 4 – 1 represents the losses of the Joule-Brayton process.
The area enclosed by 1 – 2 – 3 – 4 – 1 represents the gas turbine performance.
The losses plus the gas turbine performance give the heat input to the gas turbine which
is the product of fuel mass flow rate and the heating value of the fuel.

Thus, the efficiency of the cyclic process which is given by the ratio

GT performance
Heat input

can be calculated using the entries into the T-s-diagram

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2.2 Main Components of the Gas Turbine

Fig. 2.3

Siemens/KWU gas turbines are single-shaft machines of a single-casing design. These

turbines are suitable for operation with both gaseous and liquid fuels, such as natural gas
and light fuel oil.
The gas turbine consists essentially of a multiple-stage axial compressor, an annular
combustion chamber and a multiple-stage axial turbine. The compressor and the turbine
have a common rotor which is supported by two bearings, located outside the
pressurised region.
The compressor consists of four groups of stages. At the spaces in between so-called
blow off lines are arranged which are open if the turbine operates at a speed deviating
from the nominal speed.
The compressed air is collected in the outer annulus which forms the plenum chamber
(ring combustion chamber) for the 24 burners. At the burners the fuel is mixed to the air
and burnt. The hot gases are expanded through the turbine in stages by a series of
rotating and stationary blades. As the high-energy gases expand through the stationary
blades a portion of the thermal energy is converted into kinetic energy. The kinetic
energy is then transferred to the rotating blades and converted into work.
The exhaust gas leaves the turbine through the exhaust diffuser.
Two front supports are designed as fixed points which can be adjusted in all directions.
At the rear, the assembly is supported on flexible struts with an additional center guide,
allowing for free axial and radial casing expansion but conserving the center line.

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2.3 Siemens GT-Series

Fig. 2.4

The Siemens gas turbines can be classified according to their speed:

-1
V94.x with 50 s
V84.x with 60 s-1
V64.x with 90 s-1
The modern Siemens gas turbines are equipped with an annular combustion chamber
and are designated by the affix .3A.
The gas turbines feature different power levels:
V94.3A: 255 MW at 50 Hz
V84.3A: 180 MW at 60 Hz
V64.3A: 70 MW with a step down gear box to 50 and 60 Hz
Their design follows the same principles. The most dimensions are subject to scaling
using the speed ratio as a scaling factor.

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3 HEAT RECOVERY STEAM GENERATOR (HRSG)

TRAINING OBJECTIVES

After the chapter 3 “Heat Recovery Steam Generator” has been dealt with, the trainee
should be able to:
• describe the main stages of the schematic Clausius-Rankine process
• sketch the Clausius-Rankine process in a T-S-Diagram
• name the main components of the drum boiler
• explain the main processes in the drum boiler
• describe the main stages of the triple pressure reheat steam cycle
• explain the main processes of the triple pressure reheat steam cycle
• sketch the triple pressure reheat steam cycle
• sketch the main processes of the triple pressure reheat steam cycle in the heat
transfer diagram of the HRSG
• name the main parts of the horizontal/vertical HRSG arrangement

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3.1 The Steam Generation Process

Fig. 3.1, Fig. 3.2

The heat recovery steam generator (HRSG) uses the heat of the flue gas to produce the
steam for the steam turbine, thus converting heat energy into mechanical energy.
Contrary to the Joule-Brayton Cycle of the gas turbine the Clausius-Rankine Cycle of the
heat recovery steam generator together with the steam turbine and the condenser uses
steam as the working medium, which is produced in the heat recovery steam generator.
Considering the ideal Clausius-Rankine cycle, the cold condensate at saturation
pressure of the condenser is routed to the HRSG via the condensate and feedwater
pumps thus its pressure being increased to the working level of the steam turbine. The
shown transition from 1 to 2 in the T-S-Diagram is exaggerated in the sense, that
during the pressure increase of the condensate its temperature increase is negligible.
Within the HRSG the water is first heated up to the evaporation point by the hot turbine
exhaust gas, thereby its temperature and entropy being increased (at constant pressure)
according to the heat added. At the evaporation point water is converted to steam at
constant temperature (and pressure), its entropy being increased considerably due to the
added evaporation heat. After complete evaporation the steam is heated up further thus
increasing its temperature (at constant pressure) and entropy; this process usually is
called superheating. In short, the transition from 2 to 3 describes the production of
superheated steam from the cold pressurized condensate.
The superheated steam exits the HRSG at 3 and expands from 3 to 4 in the steam
turbine, producing mechanical work. During the expansion process the temperature and
pressure of the steam decrease, whereas the entropy remains (almost) constant.
In the condenser the condensation heat of the steam is removed during condensation
and transferred to the environment via the cooling water system. In this way the
Clausius-Rankine-Cycle is closed. The corresponding transition from 4 to 1 is
responsible for the main losses not only in the Clausius-Rankine cycle but in the whole
combined cycle power plant.
The area below the line 1 – 4 represents the losses of the Clausius-Rankine process.
The area enclosed by 1 – 2 – 3 – 4 –1 represents the useable work of the process.
From Fig. 3.2 it is evident, that superheating increases the efficiency of the process
considerably; furthermore it avoids running the steam turbine in the deep wet region.

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3.2 General Design

Fig. 3.3

The HRSG is designed to include several pressure sections. These sections differ in
many details, although the principal tasks are the same: warm-up cold water, evaporate
it and (usually) superheat the produced steam. The heat source is the hot exhaust gas
from the gas turbine.
The pump feeds the water to the economizer, where it is heated up to a temperature
level near the boiling temperature, and is then routed into the boiler drum.
From the drum, water is fed through downcomers – not heated by the exhaust gas - to
the inlet header of the evaporator. It evaporates partly in the evaporator and the
water/steam mixture is fed via natural circulation in tube risers from the outlet header
back to the drum. Within the drum, steam water separation is achieved by a dedicated
water/steam separation system.
Therefore the boiler drum has the following functions:
• ensure good mixing of feedwater,
• constitute a water reserve required for the circulation system,
• allow water expansion during start-up,
• ensure a thorough water and steam separation,
Saturated steam flows from the drum to the superheater where its temperature is
increased to about 550°C.
The main steam line connects the outlet header of the superheater with the steam
turbine.
On the way through the HRSG the gas turbine exhaust gas is cooled down and leaves
the HRSG to the environment via the stack at a temperature of about 100°C. The heat
exchange between flue gas and water/steam usually takes place in counter flow process.

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3.3 Triple Pressure Reheat Steam Cycle

Fig. 3.4

The HRSG contains 3 pressure stages (HP, IP and LP) with reheat system. Each steam
stage consists typically of an economiser (not LP stage), evaporator and superheater.
The feedwater is heated approximately to boiling temperature in the economiser and fed
into the corresponding drum.
The condensate is heated to the inlet temperature level through recirculation in the
condensate preheater and cold bypass control. An economiser is not necessary in the
LP stage, as the condensate preheater heats the condensate approximately to the
boiling temperature of the LP stage. The LP feedwater therefore goes directly from the
condensate preheater to the LP drum. The LP steam is fed to the LP section of the
steam turbine.
The IP feedwater is heated up by the economiser and fed to the IP drum. The produced
steam is superheated, mixed with the outlet steam of the HP turbine via the cold reheat
line, superheated further in the reheater and then fed (hot reheat line) into the IP section
of the steam turbine.
The HP feedwater is heated up by the economiser and fed to the HP drum. The
produced steam is superheated and then fed into the HP section of the steam turbine.
The feedwater control valves serve to control the supply of the necessary corresponding
feedwater quantity. The feedwater quantity typically is run in dependence of the
evaporator outlet enthalpy or the vessel level.
Desuperheaters are designed to keep the steam temperature constant over a wide load
range. Feedwater is used through spray nozzles to lower the temperature of the super-
/reheated steam.

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3.4 Heat Transfer Diagram of the HRSG

Fig. 3.5

On the way from the HRSG inlet down to the stack, the hot flue gas transfers heat to the
water/steam system thereby cooling down. This heat is first used to increase the
temperature of the liquid condensate and then to evaporate the preheated condensate at
three different pressures at the corresponding three different boiling temperatures: in the
LP-, IP- and HP-stage. During the evaporation process the temperatures remain
constant. Finally the steam produced in the corresponding stages is then superheated at
constant pressure thereby increasing its temperature.
Concerning the size of heat transfer in a single stage, it is largest in the HP evaporator
(typically 60 MJ/s). Another important heat transfer region is the hot exhaust gas section,
where both the HP superheater and the IP reheater are located. Also the cold exhaust
gas region contributes substantially, where the cold condensate is warmed up.

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3.5 HRSG Arrangement

Fig. 3.6, Fig. 3.7

The two main design types for the HRSG are the vertical and the horizontal boiler. As an
example Fig 3.7 shows a two pressure design of the HRSG with feedwater tank.
An advantage of the vertical design is the smaller area occupied at the ground level, and
also the shorter chimney installed on the top of the boiler. A disadvantage of this boiler
type is the diversion of the flue gas flow from the horizontal to the vertical direction
causing an additional stress on the lower parts of the boiler.
Regarding the vertical boiler, natural circulation inside the evaporators is not possible as
the heat exchanger tubes are installed horizontally. Therefore circulation pumps have to
be used to force the water/steam circulation inside the evaporators.
The complete heat exchanger modules with their headers and tube sheets are contained
in gas tight enclosure made of welded steel panels and structural steel beams. The
casing is not cooled and is externally insulated. The heat exchanger modules are
constituted by bundles of serpentine tubes installed in parallel and at both ends welded
to the distributors/headers which are located outside the gas path.
In power plants with diverter the gas turbine exhaust gas duct serves to feed the flue gas
directly to the environment (via stack) thus avoiding steam production in the case the
steam turbine is shut off and no steam is needed.

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4 WATER STEAM CYCLE

TRAINING OBJECTIVES

After the chapter 4 “Water Steam Cycle” has been dealt with, the trainee should be able
to:
• name the main systems of the water/steam cycle
• give the approximate pressure of the HP-, IP- and LP-main steam
• give the approximate temperature of the HP-, IP- and LP-main steam
• give the approximate flow rate of the HP-, IP- and LP-main steam
• give the approximate temperature and pressure of the cold reheat steam
• give the approximate temperature and pressure of the condensate before entering
the condensate preheater
• give the approximate temperature of the condensate after leaving the condensate
preheater

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4.1 Water Steam Cycle of a Single Shaft Arrangement

Fig. 4.1, Fig. 4.2

The water/steam systems connect the HRSG with the steam turbine
The main steam systems feed the HP-, IP- and LP-part of the steam turbine (ST) with
superheated steam, which is produced in the HRSG parts concerned.
The HP-main steam system connects the HP-superheater with the HP-steam turbine. It
also supplies steam to a HP-bypass (or reducing) station, if more steam is produced in
HP-superheater than the ST demands during normal operation and start-up/shutdown, or
in the event of ST trip. In these cases HP-steam will be diverted to the cold reheat
system via pressure reducing valve.
The cold reheat system receives exhaust steam from the HP-steam turbine and IP-
steam, generated in the IP-superheater, and feeds the united steam to the HRSG reheat
section inlet.
The reheated IP-steam is routed to the IP-steam turbine via the hot reheat piping
system.
The LP-main steam system discharges superheated LP-steam from the HRSG
concerned, receives exhaust steam of the IP-ST and feeds the LP-ST. Whenever
necessary (e. g. ST trip) the IP- and LP-steam can be bypassed via bypass stations into
the steam turbine condenser.
The condenser ”condenses” the arriving steam that is exhausted from the LP-steam
turbine or supplied via IP/LP-bypass stations. It works under vacuum conditions and is
also used for condensate deaeration (removing of non-condensable gas). The
condensing surfaces (tubes) are cooled by circulating water.
The condensate system feeds the condensate from the condenser to the feedwater
system and to the LP section of the HRSG. For condensate conveying there are
provided condensate extraction pumps (CEP).
To avoid flue gas condensation and therefore acid corrosion at the preheater, the flue
gas temperature has to be kept above a fixed temperature. This is achieved by
recirculation of the preheated condensate to the preheater inlet.
On its way to the feedwater system and LP-steam generator, the condensate is
preheated in the condensate preheater of the HRSG.
The feedwater system supplies water via the HP/IP-FWP (feedwater pumps) to the HP
and IP sections of the HRSG.

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4.2 Water Steam Cycle of a Multi Shaft Arrangement

Fig. 4.3

In a multi shaft arrangement, the flow rates, pressures and temperatures within each of
the two HRSG are typically very similar to those of the single shaft arrangement if the
power of the gas turbines is the same in both cases.
The flow rate of the condensate as well as that of the steam at the corresponding inlet of
the steam turbines is doubled in the double shaft arrangement.
In power plants with feedwater tank deaeration can be performed in the feedwater tank
additionally to the deaeration in the condenser.

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5 STEAM TURBOSET

TRAINING OBJECTIVES

After the chapter 5 “Steam Turboset” has been dealt with, the trainee should be able to:
• calculate the power of the 3 turbines from the corresponding enthalpies and flow
rates
• name the 4 different Siemens steam turbine series for CCPP
• give the speed of the Siemens steam turbine series
• name the main parts of the steam turbine

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5.1 Main Parameters at a Steam Turbine

Fig. 5.1

The steam turbine plant converts the thermal energy of the steam generated by the
HRSG into mechanical energy. To do so, the thermal energy represented by the
temperature/pressure gradient is converted within the turbine into kinetic energy and the
turbine blading converts this kinetic energy into mechanical energy of the shaft. That
fraction of the thermal energy which could not be converted in the turbine into
mechanical energy is dissipated in the condenser by the cooling water.
Fig. 5.2

The steam enters the 3 stages of the turbine via the corresponding emergency stop
valves and the subsequent control valves.
The steam temperature at the inlet of the HP- and IP-turbine respectively is nearly the
same and therefore also the corresponding enthalpy, although the inlet pressure at the
IP-turbine is considerably lower than that of the HP-turbine (remember that the specific
volume is approximately correspondingly higher at the IP-turbine inlet and therefore the
enthalpy does not change much with pressure). The temperature and entropy (and
pressure) of the steam is lowest at the LP-turbine inlet.
The relative pressure reduction within each individual stage increases from the HP-
turbine to the IP- and LP-turbine and therefore also the power of the corresponding
turbines. The power of the turbines of the example can be determined by multiplying the
enthalpy difference between the inlet and outlet of the corresponding turbine with the
corresponding steam mass flow:
• 25 MW for the HP turbine
• 53 MW for the IP turbine
• 55 MW for the LP turbine
The fact for the power of the HP turbine being only half of that of the IP- or LP-turbine is
of course reflected in the corresponding enthalpy; the enthalpy difference across the HP-
turbine is only half of that of the IP- or LP turbine, whereas the steam mass flow does not
change considerably from HP to IP and LP (consider, that the LP-steam from the LP-
superheater enters the LP-turbine together with the exhaust steam of the IP-turbine).

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5.2 Siemens Steam Turbine Series

Fig. 5.3

Siemens steam turbines are classified according to certain important

construction/process parameters:
• E series single casing construction
• DN series double shell construction with LP turbine section
• HE series HP turbine section with single flow combined IP and LP turbine
section
• KN series compact construction with LP turbine section

Regarding the E series and DN series the steam from the HP turbine section is fed to the
LP turbine section without reheating whereas regarding the HE series and KN series the
steam is reheated after the HP stage and then fed to the IP turbine section. Furthermore
the maximum pressure for the E series and DN series is 80 bar and 140 bar for the HE
series and KN series. The E series and DN series are used for dual pressure HRSG and
the HE series and KN series for triple pressure HRSG.
The maximum steam temperature is for all turbines 540 °C, also for the reheated steam
with the HE series and KN series.
The turbine can also be described by the number of directions, steam flows to the
exhaust from the turbine. The number of directions (paths) required depends on the
amount of steam and the specific volume (pressure) of the steam. A single-flow turbine
has the steam flowing in one direction and exhausting at one end of the turbine. Double
flow turbines have two steam flow paths. The steam enters the center of the turbine and
flows in two opposite directions (N-turbine in the DN and KN Series).
All Siemens turbines for CCPP are condensing turbines where the condensation heat of
the exhaust steam is removed by the cooling water in the condenser. The DN series and
the KN series are designed with lateral condenser, whereas the E series and the HE
series with axial condenser.
Siemens steam turbines run at 3600 rpm in a 60 Hz grid, the power ranging up to 200
MW, and at 3000 rpm in a 50 Hz grid the, power ranging up to 300 MW.

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5.3 Main Components of the Siemens Steam Turbines

5.3.1 Siemens Steam Turbine E-Series

Fig. 5.4

The condensing turbine is a single shaft machine with HP section and LP section
integrated.
The E-turbine is a single-flow construction of double shell design. A stationary blade
carrier and two stationary blades are supported in the inner casing.
At the front side the turbine outer casing is supported by two support brackets on the
front bearing pedestal. At the exhaust side it is supported on the foundation by brackets
welded to the exhaust casing.
The rotor of the E-turbine section is supported in two bearings, a combined journal-thrust
bearing at its front end and a journal bearing at its rear end..
To compensate the axial thrust into the exhaust side of the HP-turbine, produced by the
moving blades a balance piston is provided.
The initial steam is admitted ahead of the HP-blading. Having left the HP blading the
steam passes the space between inner and outer casing, mixes with inlet steam and
enters the LP blading.

5.3.2 Siemens Steam Turbine DN-Series

Fig. 5.5

The condensing turbine is a single shaft machine with one single flow and one double
flow cylinders. In the first, the D-turbine, the HP section is integrated and in the second,
the N-turbine, the LP section is integrated.
The H-turbine is a single-flow construction with double shell casing The inner casing
carries the stationary blading and is centered in the outer casing.
The N-turbine consists of a double flow unit and has a welded outer casing and a cast
inner casing. The outer casing is connected to condensers on both sides.
The bearing pedestal before the H-turbine and the pedestal between the H- and the N-
turbine sections are anchored on the foundation, separately from the turbine section
casings.
The rotor of the H-turbine section is supported in two bearings, a combined journal-thrust
bearing at its front end and journal bearing a at its rear end. The rotor of the N-turbine

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sections supports on the rotor of the H-turbine at its front and is radially supported in the
journal bearing pedestal at the rear end.
To compensate the axial thrust into the exhaust side of the HP-turbine, produced by the
moving blades a balance piston is provided.
Main steam enters the inner casing of the D-turbine through the HP admission and flows
through the blading of the HP section. A connection provided on the outer casing top
section passes the steam through the cross-over pipe to the N-turbine. The exhaust
steam flows through the lateral section of the outer casing to the condenser.

5.3.3 Siemens Steam Turbine KN-Series

Fig. 5.6

The condensing turbine is a multi-shaft machine with two individual cylinders. In the first,
the K-turbine, the HP section and IP section are integrated and in the second cylinder,
the N-turbine, the LP section is integrated.
The K-turbine is a double shell construction with double shell casing. The inner casing
carries the stationary blading and is centered in the outer casing.
The N-turbine consists of a double flow unit and has a welded outer casing and a cast
inner casing. The outer casing is connected to condensers on both sides.
The bearing pedestals are anchored on the foundation. The first turbine section rests on
lateral supporting arms on the first and second bearing. The second turbine section rests
also on lateral supporting arms on the second and third bearing pedestal.
The rotor of the first turbine section is supported in two bearings, a combined journal-
thrust bearing at its front end and a journal bearing at its rear end. The rotor of the N-
turbine section also supports on a journal bearing at the rear end.
To compensate the axial thrust of the K-turbine, produced by the moving blades a
balance piston is provided.
Main steam enters the inner casing of the K-turbine through the HP admission and flows
through the blading of the HP section in direction of the front bearing pedestal. An
exhaust connection arranged on the outer casing bottom section passes the steam from
the inner casing to the reheater. The steam leaving the reheater is also passed via the
admission inserts into the inner casing and flows through the second expansion area to
the second turbine section. A connection provided on the outer casing top section
passes the steam through the cross-over pipe to the N-turbine. The exhaust steam flows
through the lateral section of the outer casing to the condenser.

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5.3.4 Siemens Steam Turbine HE-Series

Fig. 5.7

The condensing turbine is a single shaft machine with two single flow cylinders. In the
first, the H-turbine, the HP section is integrated and in the second, the E-turbine, the IP
and LP sections are integrated.
The H-turbine is a single-flow construction with double shell casing stationary blade
carrier and outer casing.
The E-turbine consists of a single flow inlet casing of the two shell design and outer
casing and blade carrier. The exhaust casing integrates stationary blade rings as well as
bearing.
The bearing pedestal before the H-turbine and the pedestal between the H- and the E-
turbine sections are anchored on the foundation, separately from the turbine section
casings.
The rotor of the H-turbine section is supported in two bearings, a journal bearing at its
front end and a combined journal-thrust bearing at its rear end. The rotor of the E-turbine
sections supports on the rotor of the H-turbine at its front and is radially supported in the
integrated bearing pedestal at the rear end.
To compensate the axial thrust into the exhaust side of the HP-turbine, produced by the
moving blades a balance piston is provided.
The initial steam is admitted ahead of the HP-blading and leaves the exhaust section to
the reheater. The reheat steam is passed to the IP blading of the E-turbine section.
Having left the IP blading the steam passes the space between inner and outer casing,
mixes with inlet steam and enters the LP blading.

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6 SINGLE LINE DIAGRAM AND GENERATOR

TRAINING OBJECTIVES

After the chapter 6 ”Single line diagram and generator” has been dealt with, the trainees
should be able to:
• give the main voltage levels of a combined cycle power plant
• name the systems needed for start-up and emergency cases.
• explain the task of the 220 V batteries
• describe the consumers, which are connected to the MV and the LV switchgear
respectively
• name the main mechanical components of the generator
• explain the differences between a TLRI and a THRI generator?
• describe the task of the SFC
• name the demands for the SEE in the automatic mode

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6.1 General

Fig. 6.1

The essential task of a power plant is to deliver electrical energy to the high-voltage
distribution grid. Connected to this electrical grid system are the consumers (electrical
components). Furthermore, the demand of the electrical auxiliary supply system of the
power plant itself has to be covered.
The electrical plant is designed to meet the varying requirements of the grid system and
the auxiliary supply system. The main components of the electrical plant are
• the generator for the conversion from mechanical into electrical energy,
• transformers and converters for transformation of electrical energy of different voltage
levels,
• switchgears, circuit breakers and
• measuring transformers.
The following voltage levels are typical for a power plant:
• High voltage switchgear (HV)
• Medium voltage switchgear (MV)
• Low voltage switchgear (LV)
• Low voltage switchgear DC
The electrical energy produced in the power plant is delivered to the HV distribution grid.
The voltage level of this grid is usually constant in a country.

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6.2 Electrical Plant

Fig. 6.1

The generator is connected via single phase insulated bus ducts to the generator
breaker and unit transformer. There is a branch between the generator breaker and the
unit transformer in order to supply the electrical unit auxiliary system. Via the auxiliary
transformer the power supply is ensured to a medium voltage switchgear and via low
voltage transformer to low voltage switchgears. For the energy conversion from AC low
voltage to DC voltage level AC/DC converters are installed.
For the cases of start-up and of emergency, additional systems are used. Often, there is
a standby off-site grid connection for getting the start-up power. Emergency diesel
generators work as standby power supply for emergency boards. Their task is to ensure
a safe shutdown of the turbine in case of a station blackout. Sometimes, bigger diesel
generators are installed in order to supply the electrical energy to start-up the turbine if
the grid is black. The biggest additional consumer for start-up is the SFC which will be
run on less power for a blackstart. These blackstart diesel generators can also be used
as emergency diesel generators.
The electrical equipment and the I & C equipment are usually installed in predesigned,
standardized and premanufactured power control centers (PCC).

6.2.1 Power Operation

Fig. 6.2

During start-up the machine is accelerated to nominal speed. Then, the voltage produced
and its phase shift is matched to that of the HV transmission grid („synchronizing“). The
synchronizing may be done by the unit breaker or - if installed - by the generator breaker.
When this is done, the generator is connected to the high voltage switchyard via the unit
transformer. In this way electrical energy is fed to the national grid system.
A smaller part of the produced electrical energy is fed to the auxiliary power supply
system. This auxiliary power is taken from the generator busbar and fed to the medium
voltage switchgear via the unit auxiliary transformer.
Big electrical consumers and subdistributions with power requirements more than
approx. 200 kW are connected to the medium voltage switchgear and such with less
than approx. 200 kW are connected to the low voltage switchgear. The LV switchgear
feeds all actuators, lighting distributions etc. concerning the turbine unit. For control and
protection equipment DC switchgears are provided.
In power operation all incoming breakers to the MV, LV and DC switchgears are normally
closed, so that all switchgears are energized and the consumers are fed from the
generator.

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6.2.2 Start-up Operation and Standby Power Supply

Fig. 6.1

In the start-up operation and the standstill phase the power required for standstill or start-
up of the turbine may be ensured by means of the national grid. This is done if there is
no local power supply (e. g. another unit) is available. In this case a generator breaker is
needed besides the unit breaker. The generator breaker is open until the generator is
synchronized. Synchronizing by the unit breaker will only take place for resynchronising
after a load rejection.
If there is a local power supply, it will deliver the electrical energy needed to start-up the
turbine and one is not forced to pay the start-up power taken from the national HV grid.
In this case a generator breaker is not needed. The generator will be synchronized by
means of the unit breaker.
In the start-up operation the generator is running in the motor principle by means of the
static frequency converter (SFC) which is connected to the generator busbar. Thus,
electrical energy is spent to bring the unit to 70 % of nominal speed. The gas turbine is
not able to accelerate on its own from standstill or turning gear operation because of the
high load torque of the compressor.
In case of the standstill of the power plant the auxiliary systems are energized via the
auxiliary transformers.

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6.2.3 Emergency Electrical Supply

Fig. 6.1

To ensure a safe shutdown of the unit in case of a black out in the unit or the national
grid system, emergency diesel generators and DC-batteries are provided to supply the
necessary power. All loads needed to bring the unit to a safe standstill in case of a black-
out in the power station are fed from the emergency boards. The energy will be supplied
by diesel generators, which are running up automatically.
The emergency diesel set provides emergency supply to emergency electrical
equipment, battery chargers, emergency lighting system and control and instrumentation
equipment.
In case of total black-out, this means black-out of the electric mains and the fuel supply,
the gas turbine has to be brought to standstill safely. In this case the 220 V batteries
provide the power for the DC consumers (DC-oil pump) and via DC/DC converters the 24
V DC for the control, protection and alarm systems, thus ensuring the secure run down of
the turboset without manual interventions. Furthermore an uninterruptible AC power
supply (UPS) is provided for important I&C consumers, e.g. computers.

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6.3 Generator

6.3.1 General features

Fig. 6.2

The synchronous machine is the component of central importance for generation of

three-phase AC power in a power plant. The synchronous generator converts the
mechanical energy of the turbine into electrical energy.
A standard synchronous generator essentially consists of a rotor magnetized by DC field
current and a stator with three coil systems. The term ”synchronous machine” is based
on the fact that the rotor runs in synchronism with the rotating stator magnetic field.
The speed of the synchronous generator is given by the speed of the rotor.
The stator core comprises stacks of low loss laminations. The individual laminations are
insulated from each other to suppress eddy currents. A symmetrical, three-phase
winding is inserted in the slots of the stator core. The stator core is connected to the
stator frame by flexible structural elements.
The welded stator frame supports the stator core and the three-phase winding. The
accommodation of loading occurring in the event of short circuits demands an
appropriately rugged stator frame design features of hydrogen-cooled generators are
leak-tightness and compressive strength.
The slots in the solid rotor body bear the exciter winding which carries direct current. The
centrifugal forces of the end windings are absorbed by rotor end-bells.
The rotor winding is supplied with DC current from the so-called static excitation
equipment (SEE). It sets up the magnetic field of the rotor. During star-tup SFC and SEE
work together closely. Therefore, they are installed in one set of cabinets.

6.3.2 Siemens Generator Series

Fig. 6.3

With its six series of turbogenerators, Siemens covers the power range from 10 to 2000
MVA. The combination of coolant and method of cooling used for the stator and rotor
windings characterize these six series.
With increasing generator rating, cooling has to be intensified. Whereas air is the
principal coolant used in the range up to around 300 MVA, water for direct conductor
cooling and hydrogen are also used for high-rating machines. In generators with direct

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water-cooled windings, hydrogen is required to cool the stator core, as is the case with
direct, hydrogen-cooled windings.
The type of coolant and cooling method dictate the design features of the stator and rotor
slots.

6.4 Static Frequency Converter

Fig. 6.4

The electric generator is operated as synchronous motor during start-up. As the variable
speed and the frequency to be fed are in a fixed relation, a start-up converter (“static
frequency converter” SFC) has to be installed.
The gas turbine set can be started from standstill or from turning speed. At ignition
speed, the gas turbine starts driving the shaft after the ignition of the main flame.
Somewhat below 50% of nominal speed the driving torque of the gas turbine is equal to
the load torque of the compressor, and at higher speeds the gas turbine is able to
accelerate by its own power. Due to the requirement to speed up very fast through
various critical speeds it is necessary to support the acceleration with the electric motor
up to 70% nominal speed.
The SFC receives electric power from the public grid system via the generator
transformer and medium voltage switchgear. The motor is magnetically excited by a
static thyristor rectifier set. The generator stator voltage is controlled by these thyristors.
The control of the SFC is performed by the control system SIMADYN D.

6.5 Static Excitation Equipment

Fig. 6.4

The static excitation equipment (SEE) converts a 3-phase AC to DC to generate the

magnetic field in the generator (excitation). By feeding a direct current into the winding of
the generator rotor the latter becomes a strong 2-pole electric magnet. The strength of
the field is a measure of the power produced in the generator. Thus the excitation of the
generator rotor is necessary to generate a generator voltage and therefore a prerequisite
for transducing the turbine power via the generator into the electrical grid. The excitation
system has to run during SFC operation, synchronizing and load operation.
Besides producing active turbine power it is possible to generate reactive power:
inductive reactive power by overexcitation and capacitive reactive power by
underexcitation.
According to the task of the excitation system to ensure correct excitation current, it is
designed for two modes of excitation:

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• Manual mode (emergency operation or service or commissioning)
• Automatic mode (called automatic voltage regulator AVR) complying with the
following demands:
- to control start-up excitation current and voltage during motor operation
- to control the generator voltage
- to control the reactive power
- to smooth active load oscillations
- to limit the temperature in the stator winding
- to limit the temperature in the rotor winding
- to ensure maximum excitation current for stability

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7 I & C CONCEPT

TRAINING OBJECTIVES

After the chapter 7 ”I & C Concept ” has been dealt with the trainee should be able to:
• name the 6 subsystems of the I & C system TELEPERM XP
• explain the tasks of the OM and the AS system
• give examples where I&C systems other than TXP are used

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7.1 Structure of the TELEPERM XP

Fig. 7.1

TELEPERM XP is the process control system in power plants of any type and size.
Because of the modular structure its performance can be well adapted to the
requirements of both small- and large-scale power plants, which guaranties an
economical automation.
The process control system TELEPERM XP offers all process and control utilities
required for the automation, operation and monitoring and recording of processes. The
functions of the process control system are distributed between sub-systems, which form
a complete process and control system.
OM Operating and Monitoring system; to give manual commands and gather
information for operation and monitoring purposes.
ES Engineering System; configuration.
DS Diagnostic System; diagnostic system for finding and analyzing I&C faults
AS Automation System; system for automating processes
CT Commissioning Tool; operating device for maintenance and failure detection
LAN Local Area Network; communication system

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7.2 Task of the TELEPERM XP

Fig. 7.1, Fig. 7.2

The process is controlled by the process operation and monitoring system with the help
of monitors via corresponding terminals. The open- and closed-loop control and the
monitoring of the plant is carried out by the automation system. The plant bus represents
the communication link between the sub-system process operation and monitoring and
the sub-system automation. The task of the engineering system is to configure the
subsystems and the communication links, and provides documentation as far as
instrumentation and control are concerned. The operating terminals required to operate
the respective sub-systems are connected to the terminal bus and are equipped with
monitors necessary for indication and operation.
Operation and Monitoring System OM
The process operation and monitoring system OM provides the interface between the
plant and the operator in the control room, allowing to operate and monitor the plant.
Additionally, the system offers all required functions to prepare a protocol of the process
and register the data in full detail.
Engineering System ES
The engineering system is the configuration center of TELEPERM XP. It is responsible
for configuring the automation system AS, the operation and monitoring system OM, the
bus system and the required hardware. A special configuration package is assigned to
each target system. The ES administrates all configuration data centrally, which means
the data have to be entered only once.
Diagnostic System DS
The diagnostic system DS is the tool for monitoring and for the detailed detection of
failures of the instrumentation and control components which make up TELEPERM XP.
In case of failure the diagnostic system leads the operator to the location, where the
failure has occurred. It also indicates the cause of failure and how it can be eliminated.
Automation System AS
The sub-system AS runs the automation tasks in order to perform process control. The
AS gathers measured values and inherent conditions of the process. It has open- and
closed-loop functions and transmits the resulting values or corrections and commands to
the process.
Simultaneously, the AS serves other sub-systems as an interface to the processes taking
place in the system. It transmits commands from the operation and monitoring system
OM to the process. Vice versa it gathers information from the process, which is required
in the OM system, ES or DS and forwards it to the super-imposed operating and
monitoring level.
The tasks of the automation system AS are distributed on the following levels of the
instrument and control pyramid:

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Power plant process level:
At the power plant process level the sensors are situated, which gather the signals from
the process and the actuators, by means of which the automation system influences the
process. It comprises transducers, alarms, switch gears, actuators, solenoid valves. Input
and output modules in distributed configuration are also found at the power plant process
level and are connected by the bus to the programmable controller.
Automation level:
The automation level consists of automation processors, which are responsible for open-
and closed-loop control and protection tasks. These processors are the central
components of all AS degrees.

7.3 SIMADYN D

Fig. 7.3

For fast closed-loop control tasks the cycle time of the TELEPERM XP (100 ms) is too
slow. Therefore the GT controller and normally also the automatic voltage regulator of
the excitation system are realized in SIMADYN D (cycle time 4 ms).
The gas turbine controller is the control equipment that addresses the fuel valves as final
control elements and thereby sets the flow of fuel gas and oil. For this the control system
SIMADYN D is used. It is a digital automation system for fast closed-loop control and
calculation, for fast open-loop control and monitoring and for fast report and record. The
functions of this automation system are:
• Low-stress start-up and shutdown
• Synchronizing with the grid
• Loading of the turbine
• Frequency stabilization
• Reliable load rejection to unit auxiliary power requirement
• Ability to ride out a load rejection
• Prevention of overloading of the compressor
• Prevention of thermal overloading of the gas turbine
The start-up control system is used to control the gas turbine run-up from about 33% to
100% nominal speed. The run-up process is ended by limiting the valve lift with the
speed controller.
The speed/load controller is used to precisely control the nominal frequency, to match
the turbine speed to the grid frequency during synchronization and to limit overspeed in
the event of large-scale load rejection. After disconnecting the turbine generator from the
grid the speed is restored to nominal speed at auxiliary load or at zero load.
In power operation the speed/load controller controls the turbine. Provision is made for
application of a frequency component to the controller. This allows the turbine primary

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frequency control. The controller is sufficiently robust to deal with a wide range of
operating modes and configurations of the operators electrical grid in a dynamically
stable way.
Shutdown to zero load, turbine generator auxiliary power load and a large number of
possible load islands can be handled.
The temperature controller allows the operation of the GT with a constant turbine outlet
temperature. The maximum permitted GT load can also be limited by the of temperature
controller.

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8 PLANT SYSTEMS COOPERATION

TRAINING OBJECTIVES

After the chapter 8 “Plant Systems´ Cooperation” has been dealt with, the trainee should
be able to:
• name some principal and ancillary systems of the power plant
• name the three different kinds of controls of the unit control
• describe the function of the open loop control
• describe the function of the closed loop control
• sketch the gas and steam turbine speed and power as a function of time during start-up
of the power unit
• sketch the main steam flow as a function of time during start-up of the power unit

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8.1 Principal / Ancillary Systems and Their Control

Fig. 8.1

The power station consists of an assembly of systems which have to cooperate. This co-
operation is organised by the unit control. The unit control comprises three different kinds
of controls:
• Unit open loop controls
• Unit closed loop controls
• Black boxes
The unit open & closed loop controls are dealing with the principal power station process, i.
e. the conversion of chemical (fuel-) energy into electrical energy whereas the black boxes
are often applied for peripheral systems.
The unit open loop control is responsible for the correct sequence of switching on
respectively off the group & sub group controls of the various systems during start-up
respectively shutdown.
The unit closed loop controls are active during the entire operation of the power station.
They transfer the selected setpoints from the operator’s inputs to the systems closed loop
controls.
Black boxes are normally provided for ancillary systems (e.g. fuel supply, auxiliary boiler,
demineralized water supply, fire fighting system, emergency diesel and many others).
Those systems have normally a local control panel. The operator in the central control
room is only informed whether or not these systems are cleared for operation. Some of
them get commands or setpoints from the unit control systems. In the event of a failure
they may limit the power station output or even they may cause a shutdown.

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8.2 Starting up the Unit / Operation

Fig. 8.2

At first, the black boxes and many manual settings (e.g. for valve positions) in the systems
must be checked. Furthermore, the operator has to select some setpoints and has to start
the Unit Co-ordination Program. At the end of this program the unit is prepared for the gas
turbine start and, consequentially, heat being put into the HRSG.
The GT is run up using the start-up converter & generator in order to make combustion air
available and igniting the main flame. At rated speed, the generator is synchronized and
connected with the grid, and the GT is loaded to minimum output. It takes typically a few
minutes from beginning of start-up to connect the GT to the grid.
As the gas turbine runs up, heat begins to enter the steam generator with the rapidly
increasing exhaust gas flow rate and temperature. Steam begins to be generated which is
used to warm-up the thick-walled components.
If the upstream steam temperature fits to the turbine conditions it is run up to warm-up
speed. Once the ST has been warmed up sufficiently, it is run up to rated speed. It takes
typically 90 to 120 minutes from beginning of cold start-up to have the steam turbine
synchronized with the grid. Steam which is not passing the steam turbine is dumped to the
condenser.
At higher load, the steam turbine valves are completely opened. The steam turbine is now
accepting the total flow produced at the steam generator. This flow is proportional to the
GT load, i. e. according to the heat input to the steam generator, so that the unit load
(preselected by the operator) is controlled by influencing the fuel flow to the GT.
If the boiler is equipped with a diverter, the Gas turbine can be run with the steam section
out of operation.

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9 LIST OF FIGURES

Fig. 1.1 The Advantage of Combined Cycle Power Plant (CCPP)

Fig. 1.2 Gas Turbine Power Plant (Simple Cycle)
Fig. 1.3 Combined Cycle Power Plant
Fig. 1.4 Sankey Diagram of CCPP
Fig. 1.5 Example: Combined Cycle Process as District Heat Application
Fig. 1.6 Simplified Combined Cycle Process with Single Shaft Turbine Set
Fig. 1.7 Typical Arrangement of a CCPP with Single Shaft Turbine Set
Fig. 1.8 Typical Arrangement (3-d) of a CCPP with Single Shaft Turbine Set

Fig. 2.1 Simplified Layout Water/Steam Cycle(Single Shaft)

Fig. 2.2 Ideal Cyclic Process: Joule-Brayton Process
Fig. 2.3 Main Components of Siemens VX4.3A Series
Fig. 2.4 Siemens 3A Gas Turbine Series

Fig. 3.1 HRSG Triple Pressure Process

Fig. 3.2 Clausius-Rankine Cycle
Fig. 3.3 General Design of a Drum-Boiler
Fig. 3.4 HRSG: Horizontal Design / Triple Pressure Reheat Steam Cycle
Fig. 3.5 HRSG Triple Pressure Process: Heat transfer Diagram
Fig. 3.6 Layout of HRSG – Exhaust Gas System (Example: with Diverter/Bypass
Stack)
Fig. 3.7 HRSG Arrangements

Fig. 4.1 Simplified Water/Steam Cycle Layout (Single Shaft)

Fig. 4.2 Water/Steam Cycle Parameters (Simplified Example)
Fig. 4.3 Simplified Water/Steam Cycle Layout (Multi Shaft)

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Fig. 5.1 Simplified Layout Water/Steam Cycle (Single Shaft)
Fig. 5.2 Main Parameters at a Steam Turbine
Fig. 5.3 Siemens Steam Turbine Series
Fig. 5.4 Main Components of the Siemens Steam Turbine E-Series
Fig. 5.5 Main Components of the Siemens Steam Turbine DN-Series
Fig. 5.6 Main Components of the Siemens Steam Turbine KN-Series
Fig. 5.7 Main Components of the Siemens Steam Turbine HE-Series

Fig. 6.1 Simplified Single Line Diagram for Combined Cycle Power Plant
Fig. 6.2 Main Components of the Generator
Fig. 6.3 Siemens Turbo Generator Series
Fig. 6.4 Static Excitation Equipment with Static Frequency Converter

Fig. 7.1 Survey of Components of TELEPERM XP

Fig. 7.2 Instrumentation and Control Pyramid
Fig. 7.3 The GT Controller SIMADYN D

Fig. 8.1 Combined Cycle Power Plant Overview (Total)

Fig. 8.2 Typical Parameters´ Trends during Cold Start-up (Simplified)

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Gas turbine power plant Combined cycle power plant

(open cycle)

Exhaust gas
Fuel Fuel
GT G GT G HRSG
Exhaust gas ST G
Fuel Fuel
GT G GT G HRSG

Existing Existing

Exhaust gas
Fuel
GT G GT G

Extension Fuel saved Extension

Assume: Extension of one existing gas turbine power plant necessary. Legend:
Options: 1) Add one identical gas turbine CCPP Combined cycle power plant
2) Add a "bottoming steam cycle" G Generator
GT Gas turbine
HRSG Heat recovery steam generator
ST Steam turbine
G Generator
Fig. 1.1 The Advantage of CCPP
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Electrical Generator Gas turbine Exhaust gas (≈550-600 °C)

power

Exhaust stack

Air
Fuel

Fig. 1.2 Gas Turbine Power Plant (Simple Cycle)

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Electrical Gas turbine Fuel Exhaust gas ≈100 °C

power

Exhaust stack
GT-generator

Heat recovery
steam generator

Air

ST-generator
Steam

Steam turbine

Condenser

Water

Fig. 1.3 Combined Cycle Power Plant

 s © Siemens AG · Power Generation Group (KWU)

Fuel heat input

100 %

Gas
turbine
Mechanical &
electrical losses

Auxiliary power Heat Radiation &

recovery mechanical losses
steam
generator Stack losses

Steam Mechanical &

turbine electrical losses
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Auxiliary power

Condenser losses

Combined cycle
net output
≈60 %

Sankey Diagram of a CCPP Fig. 1.4

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Generator Exhaust gas ≈100 °C

Electrical
power

Exhaust stack

Heat recovery
steam generator

Air Fuel

Household Industry

Fig. 1.5 Example: Combined Cycle Process as District Heat Application

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Steam Exhaust
gas

Gas turbine
Synchronous
clutch Generator
Steam turbine

Heat recovery
Condenser steam generator
Cooling Air Fuel
medium

Pumps
Condensate Feedwater

Fig. 1.6 Simplified Combined Cycle Process with Single Shaft Turbine Set
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40 m
Stack
Gas Steam Generator phase bus
Heat recovery steam generator turbine Generator turbine
HP IP/LP
Boiler drum

Diffuser Condenser Transformer

20.7 m

5.5 m 0.0 m

52 m
130 m

Fig. 1.7 Typical Arrangement of a CCPP with Single Shaft Turbine Set
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Fig. 1.8 Typical Arrangement (3-d) of a CCPP with Single Shaft Turbine Set
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LP-steam LP-bypass
Hot reheat steam
Cold reheat steam IP-bypass
Stack
HP-bypass
HP-steam
CPH LP IP RH HP
Air
Fuel

G HP IP LP

Disconnect
HRSG Gas turbine Generator coupling Steam turbine
Condenser

Feedwater pumps Condensate pumps

Legend: LP Low pressure

IP Intermediate pressure
HP High pressure
RH Reheat
CPH Condensate preheater
HRSG Heat recovery steam generator

Fig. 2.1 Simplified Layout Water/Steam Cycle (Single Shaft)

 s © Siemens AG · Power Generation Group (KWU)

Fuel

3 ≈ 1200 °C

Combustion chamber
2
P
Compressor
Turbine
1 4
≈ 600 °C

Air Exhaust

Temperature
[°C] T

3
≈ 1200

Expansion
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n
tio
us
mb
Co

≈ 600
Heat quantity
∧
(= work) 4

2
Compression

e
ang
h
exc here
ure osp
t
ra tm
pe h a
15 m it
1 Te w

Entropy s

Ideal Cyclic Process: Joule-Brayton Process Fig. 2.2

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Ring - combustion
Fuel chamber Exhaust gas
Compressor
Turbine
Air
Generator
drive

Burners Support
Compressed air
Support

Fig. 2.3 Main Components of Siemens VX4.3A GT Series

 s © Siemens AG · Power Generation Group (KWU)

5,6 m

V64.3A

50/60 Hz

70 MW

8,4 m

V84.3A

60 Hz
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9,9 m

V94.3A

50 Hz

255 MW

Siemens 3A Gas Turbine Series Fig. 2.4

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LP-steam LP-bypass
Hot reheat steam
Cold reheat steam IP-bypass
Stack HP-bypass
HP-steam
CPH LP IP RH HP
Air
Fuel

G HP IP LP

Disconnect
HRSG Gas turbine Generator coupling Steam turbine
Condenser

Feedwater pumps Condensate pumps

Legend: LP Low pressure

IP Intermediate pressure
HP High pressure
RH Reheat
CPH Condensate preheater
HRSG Heat recovery steam generator

Fig. 3.1 HRSG Triple Pressure Process

 s © Siemens AG · Power Generation Group (KWU)

Steam PT
Turbine
Generator

4
2
Pump Condenser
QC
1
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Temperature
[°C]
g
tin

3
ea

Evaporation
rh
pe
Su

K
Expansion
g
tin
eh r
pr ate
ea
W

1 4
Condensation
Entropy s

2 → 3: Steam generator

Clausius-Rankine Cycle Fig. 3.2

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Steam
~ 100 °C
~ ~ 550 °C
~
Stack
to steam turbine
Boiler drum

Economizer Superheater

Evaporator

~
~ 600 °C
Exhaust gas

~
~ 30 °C
Fig. 3.3 General Design of a Drum-Boiler
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HP steam

IP steam
to / from
steam
Desuperheater Cold reheat steam
turbine
HP
bypass LP-steam

HP drum IP drum LP drum

FW-CV FW-CV

Stack

G
SH RH Evap. Eco SH Evap. Eco SH Evap. CPH

FW-CV
HP High pressure
IP Intermediate pressure
to feedwater
LP Low pressure Main
HP feedwater IP feedwater system
SH Superheater CCP condensate
RH Reheater
Evap. Evaporater
Eco Economiser
Gas turbine CPH Condensate preheater Heat recovery steam generator
CCP Condensate circulating pumps
FW-CV Feedwater control valve

Fig. 3.4 HRSG: Horizontal Design / Triple-Pressure Reheat Steam Cycle

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600
Temperature
[°C]

500

400
HP
superheater Exhaust gas line
IP
300 HP evaporator
reheater
IP superheater
200
IP evaporator
LP superheater
LP evaporator
100
Condensate preheater

0
0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 [MJ/s]
Thermal output exhaust gas

Fig. 3.5 HRSG Triple-Pressure Process: Heat Transfer Diagram

 I C 2 4 1 _ 0 1 _ S u rv e y
0 2 9 9 P C d s f © S ie m e n s A G · P o w e r G e n e r a tio n G r o u p ( K W U )

H e a tin g s u r fa c e

F ig . 3 .6 L a y o u t o f H R S G - E x h a u s t G a s S y s te m ( E x a m p le : w ith D iv e r te r / B y p a s s S ta c k )
    
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Vertical arrangement Horizontal arrangement

LP drum Feedwater storage tank

HP drum Feedwater LP drum
storage tank
HP drum

1
2
3
4
5
6

1 Preheater 4 HP economizer 6 5 43 2 1
2 LP evaporator 5 HP evaporator
3 LP superheater 6 HP superheater
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LP-steam LP-bypass
Hot reheat steam
Cold reheat steam IP-bypass

Stack HP-bypass
HP-steam
CPH LP IP RH HP
Air
Fuel

G HP IP LP Cooling
water

Disconnect
HRSG Gas turbine Generator coupling Steam turbine
Condenser

Feedwater

Feedwater pumps Condensate pumps

Condensate

Legend: LP Low pressure

IP Intermediate pressure
HP High pressure
RH Reheat
CPH Condensate preheater
HRSG Heat recovery steam generator
Fig. 4.1 Water/Steam Cycle Layout (Single Shaft)
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4.5 bar 10 kg/s 235 °C

30 bar 87 kg/s 542 °C
32 bar 74 kg/s 360 °C
Stack
114 bar 74 kg/s 548 °C
CPH LP IP RH HP
Air
Fuel 21 °C
402 MW
G HP IP LP

Disconnect
152 °C
HRSG Gas turbine Generator coupling Steam turbine
Condenser

Feedwater pumps Condensate pumps

97 kg/s

60 °C
Legend: LP Low pressure
IP Intermediate pressure
HP High pressure
RH Reheat
CPH Condensate preheater
HRSG Heat recovery steam generator
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LP-steam
Hot reheat steam LP-bypass
HP-bypass Cold reheat steam
Air Fuel HP-steam IP-bypass
gas
Exhaust
gas
G

Hot reheat steam LP-bypass

HP-bypass Cold reheat steam
IP-bypass
Air Fuel
gas HP RH IP LP CPH
G
HP IP LP
G
Steam turbine

Gas turbine Boiler

Feedwater tank Condenser

HP High pressure
RH Reheater
IP Intermediate pressure
LP Low pressure
Fig. 4.3 Simplified Layout Water/Steam Cycle (Multi Shaft) CPH Condensate preheater
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LP-steam LP-bypass
Hot reheat steam
Cold reheat steam IP-bypass
Stack
HP-bypass
HP-steam
CPH LP IP RH HP
Air
Fuel

G HP IP LP

Disconnect
HRSG Gas turbine Generator coupling Steam turbine
Condenser

Feedwater pumps Condensate pumps

Legend: LP Low pressure

IP Intermediate pressure
HP High pressure
RH Reheat
CPH Condensate preheater
HRSG Heat recovery steam generator

Fig. 5.1 Simplified Layout Water/Steam Cycle (Single Shaft)

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4.29 2930.5
10.2 234.1
from LP-superheater

29.55 3549.7
86.6 541.6
from hot reheat system

113.15 3480.2
73.8 547.5
from HP-superheater
32.07 3134.9
72.8 359.3 Cooling water
to cold reheat system
21 °C

HP IP LP
Condenser

Steam turbine

0.057 2357.8 0.057 147.8

97.5 x=0.914 97.8 35.3

to main condensate pumps

Legend: LP Low pressure •
IP Intermediate pressure bar kJ/kg msteam
kg/s °C (x) x= • •
HP High pressure (msteam + mwater)

Fig. 5.2 Main Parameters at a Steam Turbine

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Type Basic Speed Capability Max. operating

configuration range steam conditions
rpm MW bar °C

E series 3,000 50 - 300

G E 80 540
without reheat 3,600 30 - 200

DN series 3,000 50 - 300

D N G
80 540
without reheat 3,600 30 - 200

HE series 3,000 50 - 300

G H E
140 540/540
with reheat 3,600 30 - 200

KN series 3,000 50 - 300

K N G
140 540/540
with reheat 3,600 30 - 200

Fig. 5.3 Siemens Steam Turbine Series

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HP inner LP stator
casing blade carrier
HP/LP rotating
blades

HP admission LP admission

Combined thrust
and journal bearing

Journal
bearing
HP-rotor LP-rotor

Balance Outer casing

piston
HP/LP stator
blades

Fig. 5.4 Main Components of the Siemens Steam Turbine E-Series

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LP outer casing

HP outer
casing Rotating Stator
Balance piston blades blades

Combined thrust Journal Journal

and journal bearing bearing bearing

HP-rotor LP-rotor

HP admission
HP inner
casing

LP inner
casing

Fig. 5.5 Main Components of the Siemens Steam Turbine DN-Series

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Single-casing LP turbine with

opposed-flow downward exhaust to
HP/IP turbine underslung condenser

LP outer casing

Rotating
Balance blades
piston HP outer
casing Journal Journal
Combined thrust bearing bearing
and journal bearing

HP/IP-rotor LP-rotor

Stator
blades
HP/IP
admission
HP inner IP inner
casing casing
LP inner
casing

Fig. 5.6 Main Components of the Siemens Steam Turbine KN-Series

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HP turbine with generator IP/LP turbine with

coupling at exhaust end axial exhaust
IP/LP inner
casing
Combined thrust
HP admission and journal bearing Rotating
Balance piston blades
Journal
bearing
Journal
HP-rotor IP/LP-rotor bearing

Stator
blades
HP inner HP outer IP/LP outer
casing casing casing

IP admission
LP admission

Fig. 5.7 Main Components of the Siemens Steam Turbine HE-Series

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High voltage switchgear

High voltage breaker High voltage breaker High voltage breaker

Generator (unit) transformer Generator (unit) transformer Generator (unit) transformer

from existing
Black start
switchgear G
diesel generator
Auxiliary transformer Auxiliary transformer Auxiliary transformer

3 3
2 2 3
Medium voltage switchgear Medium voltage switchgear Medium voltage switchgear

Emergency
diesel generator
M M M M M
G
>200kW >200kW >200kW
1 4
1 4
Low voltage switchgear Low voltage switchgear Low voltage switchgear
SFC SEE SFC SEE SEE
Generator Generator
breaker breaker
~ ~ ~
M M M
Low voltage switchgear Low voltage switchgear Low voltage switchgear
DC 220V DC 220V DC 220V

M M M
Battery Battery Battery
~ DC pump ~ DC pump ~ DC pump
G Low voltage switchgear G Low voltage switchgear G Low voltage switchgear
3~ 3~ 3~
DC 24V DC 24V DC 24V
UPS UPS UPS
Gas turbine set 1 for I&C Gas turbine set 2 for I&C Steam turbine set for I&C

Fig. 6.1 Simplified Single Line Diagram for Combined Cycle Power Plant
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Endwinding Stator core with winding Terminal bushings

Bearing Bearing Sliprings

Rotor

Cooling
fan

Stator frame

Fig. 6.2 Main Components of the Generator

 s © Siemens AG · Power Generation Group (KWU)

Air cooling

Hydrogen cooling THFF

THDF
Water cooling

THDD

THRI

TLRI

TLII

0 47 100 300 420 1000 1600 2000

T L I I
T L R I
T H R I
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T H D D
T H D F
T H F F

Product:
T = Three-phase turbogenerator

Cooling gas in generator frame

L = Air
H = Hydrogen

Method of rotor cooling

I = Indirect cooling by air
R = Direct radial cooling by air or hydrogen
D = Direct axial cooling by hydrogen
F = Direct cooling by water

Method of stator cooling

I = Indirect cooling by air or hydrogen
D = Direct axial cooling by hydrogen
F = Direct axial cooling by water

Siemens Turbogenerator Series Fig. 6.3

 s © Siemens AG · Power Generation Group (KWU)

HV-Switchgear

MV-Switchgear

Excitation
Unit transformer Start-up transformer transformer

Closed loop control system

Simadyn D (AS620T)
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SFC SEE

Generator breaker

SFC Isolator

G
3~

Static Excitation Equipment with

Static Frequency Converter Fig. 6.4
 s © Siemens AG · Power Generation Group (KWU)

ES
Engineering
AS system
Automation
system
C 241 - 01 Survey

OM
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Operating and
DS
monitoring Diagnostic
system system

CT
Commissioning
tool
LAN
Local area network

Survey of the Components of TELEPERM XP Fig. 7.1

 s © Siemens AG · Power Generation Group (KWU)

Operation and
monitoring

Engineering Diagnosis
Operation and
monitoring level

ET OT DT

Communication level:
Terminal bus
~

ES OM DS Processing level

~ Communication level:
Plant bus
C 241 - 01 Survey

AS AS
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Turbine Turbine Automation level

open-loop control AS protection
Turbine
closed-loop control

M M M Power plant process level

ES Engineering system
OM Operation and monitoring system
DS Diagnose system
ET Engineering terminal
OT Operation terminal
DT Diagnose terminal
AS Automation system

Instrumentation and Control Pyramid Fig. 7.2

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Low-stress start-up and shutdown of the turbine

Synchronisation with the grid

Prevention of thermal overloading of the gas turbine

Gasturbinecontroller

Gasturbinecontroller
Gasturbinecontroller

SIMADYN D
Digital automation system
for Loading of the turbine

• fast closed-loop control and calculation

• fast open-loop control and monitoring
• fast report and record
Gasturbinecontroller

Frequency stabilisation
Prevention of overloading of the compressor

Ability to ride out a load rejection

Reliable load rejection to unit auxiliary power requirement

Fig. 7.3 The GT Controller SIMADYN D

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Control room: OM (operating & monitoring)

Unit coord Unit

CJA
Black boxes program setpoints

X E B A

Q H MB MK MA

S G L P

Fig. 8.1 Combined Cycle Power Plant Overview (Total)

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100

[%] Exhaust gas

temperature
80
Main steam
GT speed temperature

60

40
GT power Main steam flow ST power

20

ST speed

Time

Fig. 8.2 Typical Parameters´ Trends during Cold Start-up (Simplified)

s

C 241

Technology Course

Seminar Work

Overview to Design and Operation of the

Siemens Combined Cycle Power Plant (CCPP)

TD No. 01

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s
Table of Content
1 Introduction ........................................................................................................ 1-3
2 Gas Turbine Plant............................................................................................... 2-6
3 Heat Recovery Steam Generator....................................................................... 3-9
4 Water steam Cycle............................................................................................ 4-14
5 Steam Turboset ................................................................................................ 5-16
6 Single Line Diagram and Generator ............................................................... 6-19
7 I & C Concept...................................................................................................... 7-1
8 Plant Systems Cooperation............................................................................... 8-2

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1 INTRODUCTION

1. Name the main components and the related processes of a CCPP

The fuel is burned in the gas turbine and part of the fuel energy is thereby
converted into mechanical energy which then is converted into electrical energy in
the generator. The remaining energy contained in the hot exhaust gas of the gas
turbine is partly used to produce steam in the heat recovery steam generator.
The heat energy of the steam is partly converted to mechanical energy in the
steam turbine and partly released to the environment via the cooling water in the
condenser thereby condensing the steam of the steam turbine. The mechanical
energy produced in the steam turbine again is converted into electrical energy in
the generator.

2. Name the main reasons why a power plant should have a high efficiency
In order to find an answer to the question “Why CCCP?”, the total costs for
running a power plant have to be considered. These costs can be broken down to
fixed and operating costs.
Fixed costs include direct costs which are made up of items such as the cost of
equipment and materials, installation, general construction etc. and indirect costs
such as equipment testing, start up costs, miscellaneous construction expenses
and engineering services etc.
Operating costs (also called variable costs and expenses) are those costs that
vary with the level of output. For power plants, operating costs include fuel costs
and variable operation and maintenance costs. Approximately 60% of a utility’s
total revenue requirements are needed to offset operating costs; fuel is usually the
largest single component.
Therefore fuel saving is the predominant factor for cost saving (at constant power
output), with other words: power plant efficiency is the most important factor.

3. Give the efficiency of a simple cycle gas turbine power plant

38%

4. Give the efficiency of a combined cycle power plant

60%

5. Give the ratio of power of the steam turbine to the total power in a CCPP
1/3

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s
6. Describe the main processes in a gas turbine
When the gas turbine is started, ambient air is drawn through the inlet air system
and then directed to the compressor. The air is compressed by the compressor
and directed to the combustion system. Inside the combustion system, the air is
mixed with the fuel and the mixture is ignited. The compressed and heated
combustion gas then flows to the turbine. The combustion gas expands as it flows
through the turbine, causing it to rotate.
The rotating turbine drives the compressor and accessory equipment with available
excess energy to produce shaft power which drives the generator. Approximately
½ of the work produced is available to produce electricity; the other half is used to
drive the compressor. The function of the generator is to convert mechanical
energy of the turbine into electrical energy.
The gas driving the turbine is exhausted to the atmosphere in the case of the
simple cycle gas turbine process at a temperature of about 500 – 600 °C.

7. Give the ratio of the work consumed in the compressor to the total work
produced by the gas turbine
½

8. Describe the main steps of the combined cycle process

In the case of a combined cycle power plant the exhaust gas from the gas turbine
is directed through a heat recovery steam generator that generates steam at one
or more pressure levels. The steam is fed to a steam turbine that drives a separate
generator (multishaft arrangement). With this arrangement the gas turbine can be
decoupled from the operation of the steam turbine, allowing for steam turbine
shutdown with continued gas turbine operation.
The exhaust steam is directed to the condenser where it is condensed by transfer
of the condensation energy to the cooling water system. The condensate is fed
back to the heat recovery steam generator and evaporated again – thus closing
the cycle .

9. Name the main losses of a CCPP

Condenser losses

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s
10. Identify the main components of a single shaft CCPP

Fig. 1.7

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s
2 GAS TURBINE PLANT

1. Describe the 4 main stages of the Joule-Brayton process for the gas
turbine
The gas turbine consists of a compressor section, combustor and turbine section.
Ambient air is first compressed from 1 to 2 . During this process the pressure
(and temperature) of the air is increased, whereas the entropy remains constant as
no heat is added or removed.
Fuel is put into and combusted in the combustor, increasing thereby both the
temperature and the entropy of the medium, but the pressure remains constant.
The flue gas exit the combustor at 3 and expand to 4 in the turbine section.
During the expansion process the pressure (and temperature) of the air decreases,
whereas again as in the compression stage the entropy remains constant.
In a simple cycle process the heat of the expanded - but still hot - flue gas is
released to the atmosphere from 4 back to 1 . During this process both the
temperature and entropy decrease (at constant pressure of the ambient).

2. Explain the gas turbine performance in the T-S-Diagram

The area below the line 4 – 1 represents the losses of the Joule-Brayton
process. The area enclosed by 1 – 2 – 3 – 4 – 1 represents the gas turbine
performance. The losses plus the gas turbine performance give the heat input to
the gas turbine which is the product of fuel mass flow rate and the heating value of
the fuel.

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3. Name the main components of the gas turbine

Fig 2.3

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4. Classify the different Siemens GT-Series according to their speed and the
type of combustion chamber
The Siemens gas turbines can be classified according to their speed:
V94.x with 50 s-1
V84.x with 60 s-1
V64.x with 90 s-1
The modern Siemens gas turbines are equipped with an annular combustion
chamber and are designated by the affix .3A.

5. Give the power of the different Siemens GT-Series

The gas turbines feature different power levels:
V94.3A: 255 MW at 50 Hz
V84.3A: 180 MW at 60 Hz
V64.3A: 70 MW with a step down gear box to 50 and 60 Hz

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3 HEAT RECOVERY STEAM GENERATOR (HRSG)

1. Describe the main stages of the schematic Clausius-Rankine process

Considering the ideal Clausius-Rankine cycle, the cold condensate at saturation
pressure of the condenser is routed to the HRSG via the condensate and
feedwater pumps thus its pressure being increased to the working level of the
steam turbine. The shown transition from 1 to 2 in the T-S-Diagram is
exaggerated in the sense, that during the pressure increase of the condensate its
temperature increase is negligible.
Within the HRSG the water is first heated up to the evaporation point by the hot
turbine exhaust gas, thereby its temperature and entropy being increased (at
constant pressure) according to the heat added. At the evaporation point water is
converted to steam at constant temperature (and pressure), its entropy being
increased considerably due to the added evaporation heat. After complete
evaporation the steam is heated up further thus increasing its temperature (at
constant pressure) and entropy; this process usually is called superheating. In
short, the transition from 2 to 3 describes the production of superheated steam
from the cold pressurized condensate.
The superheated steam exits the HRSG at 3 and expands from 3 to 4 in the
steam turbine, producing mechanical work. During the expansion process the
temperature and pressure of the steam decrease, whereas the entropy remains
(almost) constant.
In the condenser the condensation heat of the steam is removed during
condensation and transferred to the environment via the cooling water system. In
this way the Clausius-Rankine-Cycle is closed.

2. Sketch the Clausius-Rankine process in a T-S-Diagram

Fig 3.2

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3. Name the main components of the drum boiler

Fig 3.3

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4. Explain the main processes in the drum boiler
The pump feeds the water to the economizer, where it is heated up to a
temperature level near the boiling temperature, and is then routed into the boiler
drum.
From the drum, water is fed through downcomers – not heated by the exhaust gas
- to the inlet header of the evaporator. It evaporates partly in the evaporator and
the water/steam mixture is fed via natural circulation in tube risers from the outlet
header back to the drum. Within the drum, steam water separation is achieved by
a dedicated water/steam separation system.
Saturated steam flows from the drum to the superheater where its temperature is
increased to about 550°C.
The main steam line connects the outlet header of the superheater with the steam
turbine.

5. Describe the main stages of the triple pressure reheat steam cycle
The HRSG contains 3 pressure stages (HP, IP and LP) with reheat system. Each
steam stage consists typically of an economiser (not LP stage), evaporator and
superheater. The feedwater is heated approximately to boiling temperature in the
economiser and fed into the corresponding drum.

6. Explain the main processes of the triple pressure reheat steam cycle
The condensate is heated to the inlet temperature level through recirculation in the
condensate preheater and cold bypass control. An economiser is not necessary in
the LP stage, as the condensate preheater heats the condensate approximately to
the boiling temperature of the LP stage. The LP feedwater therefore goes directly
from the condensate preheater to the LP drum. The LP steam is fed to the LP
section of the steam turbine.
The IP feedwater is heated up by the economiser and fed to the IP drum. The
produced steam is superheated, mixed with the outlet steam of the HP turbine via
the cold reheat line, superheated further in the reheater and then fed (hot reheat
line) into the IP section of the steam turbine.
The HP feedwater is heated up by the economiser and fed to the HP drum. The
produced steam is superheated and then fed into the HP section of the steam
turbine.

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7. Sketch the triple pressure reheat steam cycle
Fig 3.4

8. Sketch the main processes of the triple pressure reheat steam cycle in
the heat transfer diagram of the HRSG

Fig. 3.5

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9. Name the main parts of the horizontal/vertical HRSG arrangement

Fig. 3.7

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4 WATER STEAM CYCLE

1. Name the main systems of the water/steam cycle

Fig 4.1

2. Give the approximate pressure of the HP-, IP- and LP-main steam
Fig. 4.2

3. Give the approximate temperature of the HP-, IP- and LP-main steam
Fig. 4.2

4. Give the approximate flow rate of the HP-, IP- and LP-main steam
Fig. 4.2

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5. Give the approximate temperature and pressure of the cold reheat steam
Fig. 4.2

6. Give the approximate temperature and pressure of the condensate before

entering the condensate preheater
Fig. 4.2

7. Give the approximate temperature of the condensate after leaving the

condensate
Fig. 4.2

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5 STEAM TURBOSET

1. Calculate the power of the 3 turbines from the corresponding enthalpies

and flow rates

The power of the turbines of the example can be determined by multiplying the
enthalpy difference between the inlet and outlet of the corresponding turbine with
the corresponding steam mass flow:
• 25 MW for the HP turbine
• 53 MW for the IP turbine
• 55 MW for the LP turbine

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2. Name the 4 different Siemens steam turbine series for CCPP

Fig. 5.3

3. Give the speed of the Siemens steam turbine series

Fig. 5.3

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4. Name the main parts of the steam turbine

Fig 5.4

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6 SINGLE LINE DIAGRAM AND GENERATOR

1. Give the main voltage levels of a combined cycle power plant

The following voltage levels are typical for a power plant:
• High voltage switchgear (HV)
• Medium voltage switchgear (MV)
• Low voltage switchgear (LV)
• Low voltage switchgear DC

2. Name the systems needed for start-up and emergency cases.

For the cases of start-up and of emergency, additional systems are used. Often,
there is a standby off-site grid connection for getting the start-up power.
Emergency diesel generators work as standby power supply for emergency
boards. Their task is to ensure a safe shutdown of the turbine in case of a station
blackout. Sometimes, bigger diesel generators are installed in order to supply the
electrical energy to start-up the turbine if the grid is black. The biggest additional
consumer for start-up is the SFC which will be run on less power for a blackstart.
These blackstart diesel generators can also be used as emergency diesel
generators.

3. Explain the task of the 220 V batteries

In case of total black-out, this means black-out of the electric mains and the fuel
supply, the gas turbine has to be brought to standstill safely. In this case the 220 V
batteries provide the power for the DC consumers (DC-oil pump) and via DC/DC
converters the 24 V DC for the control, protection and alarm systems, thus
ensuring the secure run down of the turboset without manual interventions.
Furthermore an uninterruptible AC power supply (UPS) is provided for important
I&C consumers, e.g. computers.

4. Describe the consumers, which are connected to the MV and the LV

switchgear respectively
Big electrical consumers and subdistributions with power requirements more than
approx. 200 kW are connected to the medium voltage switchgear and such with
less than approx. 200 kW are connected to the low voltage switchgear. The LV
switchgear feeds all actuators, lighting distributions etc. concerning the turbine unit.
For control and protection equipment DC switchgears are provided.

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5. Name the main mechanical components of the generator

Fig. 6.2

6. Explain the differences between a TLRI and a THRI generator?

Cooling gas in generator frame: L = air, H = hydrogen
Fig 6.3

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7. Describe the task of the SFC
The electric generator is operated as synchronous motor during start-up. As the
variable speed and the frequency to be fed are in a fixed relation, a start-up
converter (“static frequency converter” SFC) has to be installed.

8. Name the demands for the SEE in the automatic mode

• to control start-up excitation current and voltage during motor operation
• to control the generator voltage
• to control the reactive power
• to smooth active load oscillations
• to limit the temperature in the stator winding
• to limit the temperature in the rotor winding
• to ensure maximum excitation current for stability

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7 I & C CONCEPT

1. Name the 6 subsystems of the I & C system TELEPERM XP

OM Operating and Monitoring system; to give manual commands and gather
information for operation and monitoring purposes.
ES Engineering System; configuration.
DS Diagnostic System; diagnostic system for finding and analyzing I&C faults
AS Automation System; system for automating processes
CT Commissioning Tool; operating device for maintenance and failure detection
LAN Local Area Network; communication system

2. Explain the tasks of the OM and the AS system

Operation and Monitoring System OM
The process operation and monitoring system OM provides the interface between
the plant and the operator in the control room, allowing to operate and monitor the
plant. Additionally, the system offers all required functions to prepare a protocol of
the process and register the data in full detail.
Automation System AS
The sub-system AS runs the automation tasks in order to perform process control.
The AS gathers measured values and inherent conditions of the process. It has
open- and closed-loop functions and transmits the resulting values or corrections and
commands to the process.
Simultaneously, the AS serves other sub-systems as an interface to the processes
taking place in the system. It transmits commands from the operation and monitoring
system OM to the process. Vice versa it gathers information from the process, which
is required in the OM system, ES or DS and forwards it to the super-imposed
operating and monitoring level.

3. Give examples where I&C systems other than TXP are used
For fast closed-loop control tasks the cycle time of the TELEPERM XP (100 ms) is
too slow. Therefore the GT controller and normally also the automatic voltage
regulator of the excitation system are realized in SIMADYN D (cycle time 4 ms).

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8 PLANT SYSTEMS COOPERATION

1. Name some principal and ancillary systems of the power plant

Fig 8.1 inside dotted boundary

2. Name the three different kinds of controls of the unit control

• Unit open loop controls
• Unit closed loop controls
• Black boxes

3. Describe the function of the open loop control

The unit open loop control is responsible for the correct sequence of switching on
respectively off the group & sub group controls of the various systems during start up
respectively shut down.

4. Describe the function of the closed loop control

The unit closed loop controls are active during the entire operation of the power
station. They transfer the selected setpoints from the operator’s inputs to the
systems closed loop controls.

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5. Sketch the gas and steam turbine speed and power as a function of time
during start-up of the power unit
Fig 8.2

6. Sketch the main steam flow as a function of time during start-up of the
power unit
Fig 8.2

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