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Overview of Gas-based and Combined

Cycle Power Plants, Working Cycles,
Benefits of Combined Cycle Power Plants

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CONTENT
 Types of Power plants
 Working Cycles
 Power Plant Fuel
 Open Cycle
 Combine Cycle
 Heat Flow / Efficiency
 Heat & Mass Balance Diagram
 Benefits of CCPP

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TYPES OF POWER PLANTS

 Thermal Power Plants

 Coal Fired (Subcritical or Supercritical)
 Gas / Oil Fired (Open Cycle or Combined Cycle)
 Hydro Power Plants
 Nuclear Power Plants
 Others (Wind, Solar)

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Installed Power Station Capacity in India as of June 30, 2016

All India (MW) Percentage (%)

Coal 186,243 61.4

Thermal Gas 24,509 211,670 8.1 69.8

Diesel 919 0.3

Hydel 42,783 14.1

Renewable 85,633 28.3
Other 42,849 14.1

Nuclear - 5,780 1.9

Total 303,083 100

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HEAT ENGINE
In thermodynamics, a heat engine is a system that converts heat or
thermal energy and chemical energy to mechanical energy, which can
then be used to do mechanical work. It does this by bringing a working
substance from a higher state temperature to a lower state temperature

1. Receive heat from high temperature source

Conversion of heat to work
2. Convert fraction of heat to work
requires a Heat engine.
3. Reject waste heat to low temperature reservoir
4. Operate in a cycle
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CARNOT CYCLE
The Carnot cycle is the most efficient heat engine that can operate
between two fixed temperatures TH and TL. The Carnot cycle is
described by the following four processes.

Process Description
1-2 Isothermal heat addition
2-3 Isentropic expansion
3-4 Isothermal heat rejection
4-1 Isentropic compression

Wnet, out
 th 
Qin

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BRAYTON CYCLE
The Brayton cycle is a thermodynamic cycle that describes the workings
of a constant pressure heat engine.
The original Brayton engines used piston‐compressor and expander
systems. Gas turbine engines also follow the Brayton cycle.

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BRAYTON CYCLE
The deviation of an actual gas‐turbine cycle from the ideal Brayton cycle
as a result of irreversibility

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RANKINE CYCLE
The Rankine cycle is a model that is used to predict the performance of
steam turbine systems. The Rankine cycle is an idealized
thermodynamic cycle of a heat engine that converts heat into
mechanical work. The heat is supplied externally to a closed loop, which
usually uses water as the working fluid.

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RANKINE CYCLE

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COMBINE CYCLE
Brayton as Topping and Rankine as Bottoming Cycle

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COMBINE CYCLE

ENTROPY

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THERMAL CYCLE - COMPARISON

Q+

Carnot Cycle
Temperature

Brayton Cycle

Combined Cycle

Q-

Entropy

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FUEL
Coal is expected to remain India’s primary
energy source.

However, Natural Gas may increase its share

by up to 20% ‐ wherein, 60% to 80% gas
supply would be used for power generation.

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FUEL
Natural Gas has emerged as the most preferred fuel due to its
inherent environmentally caring nature, greater efficiency, and
cost effectiveness.

The demand of Natural Gas has sharply increased in the last two
decades at the global level. GAS IS THE FUEL OF CHOICE FOR POWER
GENERATION IN THE 21ST CENTURY.

Moderate pricing for natural gas combined with its other

advantages – low carbon footprint, high flexibility and low
CAPEX – makes gas the fuel of choice.

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FUEL – NATURAL GAS

Natural gas is a fossil fuel formed when layers of buried plants,
gases and animals are exposed to intense heat and pressure
over thousands of years.

The energy that the plants originally obtained from the sun is
stored in the form of chemical bonds in natural gas.

Natural gas is a non‐renewable resource.

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FUEL – NATURAL GAS

Natural gas is a hydrocarbon gas mixture

consisting primarily of Methane,
but commonly includes varying amounts of other
higher alkanes and even a lesser percentage of
Carbon Dioxide, Nitrogen, Hydrogen Sulfide, or helium.

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FUEL – NATURAL GAS

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GAS FIRED POWER PLANT

During the last four decades, the development of gas turbines
has made a lot of progress.

Also due to environmental regulation, gas, as a relatively

low‐pollutant fuel, encourages the gas turbine manufacturers
to specially adapt gas turbine to power plant requirements and
to improve their thermal efficiency.

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GAS FIRED POWER PLANT

Particularly high efficiencies can be achieved through combining
gas turbines with a steam turbine in combined cycle mode.

Combined cycle power generation using natural gas is currently

the cleanest available source of power using hydrocarbon fuels,
and this technology is widely and increasingly used.

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GAS TURBINE BASED (Simple/Open Cycle)

SCHEMATIC EXHAUST

FUEL BURNER
COMPRESSOR
TURBINE

AIR GENERATOR

ELECTRICITY

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SIMPLE CYCLE – FLOW PATH

AIR INTAKE
HOUSE

FUEL

EXPANSION
BELLOWS

CLEAN AIR
COMPRESSOR TURBINE
FILTER ELEMENTS PLENUM

EXHAUST
DUCT

GENERATOR COMBUSTION
CHAMBER

LUBE OIL

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A TYPICAL GAS TURBINE (Siemens V94.2)

EXHAUST
COMBUSTION TURBINE
CHAMBER

COMPRESSOR

BURNERS

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COMBINE CYCLE – SCHEMATIC

EXHAUST Combined cycle ELECTRICITY

Simple Cycle STEAM TURBINE

HRSG
GENERATOR

GAS TURBINE FUEL PUMP

BURNER
COMPRESSOR
CONDENSER
TURBINE

AIR GENERATOR

ELECTRICITY

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HRSG
A heat recovery steam generator (HRSG) is an energy recovery
heat exchanger that recovers heat from a hot gas stream. It
produces steam that can be used in a process (cogeneration) or
used to drive a steam turbine (combined cycle).

HRSGs consist of four major components: Economizer,

Evaporator, Superheater & Water pre‐heater. The different
components are put together to meet the operating
requirements of the unit.

HRSGs can be categorized by a number of ways such as direction

of exhaust gases flow or Number of pressure levels.

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HRSG
Based on exhaust gases flow, HRSGs are categorized into vertical
and horizontal types. In horizontal type HRSGs, exhaust gas
flows horizontally over vertical tubes whereas in vertical type
HRSGs, exhaust gas flow vertically over horizontal tubes.

Based on pressure levels, HRSGs can be categorized into single

pressure and multi pressure. Single pressure HRSGs have only
one steam drum and steam is generated at single pressure level
whereas multi pressure HRSGs employ two (double pressure) or
three (triple pressure) steam drums. As such triple pressure
HRSGs consist of three sections: an LP, IP and HP section. Each
section has a economizer, steam drum, evaporator &
superheaters section.
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HRSG

Vertical Horizontal

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HRSG – CROSS SECTIONAL VIEW

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STEAM TURBINE
A steam turbine is a device that extracts thermal energy from
pressurized steam and uses it to do mechanical work on a
rotating output shaft.

Steam turbines are made in a variety of sizes ranging from small

<0.75 kW (<1 hp) units (rare) used as mechanical drives for
pumps, compressors and other shaft driven equipment, to
1 500 000 kW (1500 MW; 2 000 000 hp) turbines used to
generate electricity. There are several classifications for modern
steam turbines.

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Single Shaft Multi Shaft

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CONDENSER
In thermal power plants, the purpose of a surface condenser is
to condense the exhaust steam from a steam turbine to obtain
maximum efficiency, and also to convert the turbine exhaust
steam into pure water (referred to as steam condensate) so that
it may be reused in the steam generator or boiler as boiler feed
water.

Condenser can be classified based on the cooling medium

which condense the exhaust steam.

Water cooled Condenser

Air cooled Condenser

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COMBINE CYCLE – FLOW PATH

BYPASS STACK CHIMNEY

DRUMS

AIR INTAKE COMBUSTER

TURBINE

HRSG
Generator COMPRESSOR EXHAUST DD

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BALANCE OF PLANT SYSTEM

1. Fuel Supply system
2. Condenser Air Evacuation System
3. Extraction Steam system for Heaters
4. Demineralized (DM) Water system
5. Circulation Water (CW) system
6. Closed Cooling Water (CCW) system
7. Axillary Cooling Water (ACW) system
8. Potable water (PW) system
9. Service Water (SW) system
10. Instrument Air (IA) system

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PLANT PERFORMANCE
Gross Output (GP)
This denotes Power Output in kW at Turbine Generator
terminals.

Auxiliary Power Consumption of Plant

This denotes auxiliary power consumption of the plant before
exporting power to the client generally at the HV side of main
transformers. This includes auxiliary power of main equipment
like Turbine generators, motor input power of all motor drives,
transformer losses, C&I, bus duct losses etc.

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PLANT PERFORMANCE
Typical Aux. Power Consumption

Combined Cycle = 2.5% to 3.0%

Coal Based TPS = 5.5% to 7.5%

Net Power Output (NP)

Net Output = Gross Output – Auxiliary Power Consumption

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PLANT PERFORMANCE
Heat Rate (HR)

This is an important parameter for plant performance

evaluation.

It is basically reciprocal of efficiency and denoted in

kCal / kWh or kJ / kWh

Gross Heat Rate = Heat Input / Gross Output

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OPEN CYCLE – HEAT FLOW

Power
28 % to 39 %

GT EXHAUST HEAT
69% to 58 %

Note: Efficiency range changes with size, Model & Make

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COMBINE CYCLE – HEAT FLOW

Power
39% Power
19%

Heat Input
Gas GT Exhaust
through Fuel Heat
Turbine
100% 57.5 % 25.2%
21.7%

Note: Typical Figures based on Siemens SGT4000F, 3P, Reheat Cycle at ISO Condition
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OPEN CYCLE TO COMBINE CYCLE

 Open cycle

 100 % Heat Input

 39 % Maximum Output
 61 % Loss

 Combine cycle (Addition to open cycle)

 19 % More Output from 61 % loss

 42 % Loss as 19 % will be regain

58 % Output & 42 % Loss

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ISO CONDITIONS
Industry practice is to quote Output / Efficiency ratings at ISO
conditions
ISO Conditions:
• Inlet Air :15 deg.C
• Relative Humidity :60%
• GTG Location :0 MSL
• Fuel :Natural Gas
• Inlet / Exhaust Losses :0” / 0” of water column
• Machine Condition :New & Clean

Source: GT World

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ISO Rating of Gas Turbine Models

Model ISO Base Rating, KW Heat Rate kCal/kWh Efficiency Exhaust Flow, Exhaust Temperature,
(%) Kg/sec °C
GE

LM6000PD 47505 2056.79 41.8 131.5 446.1

6B 3-Series 43000 2597.32 33 145.1 542.2
9E 3-Series 128183 2514.92 34.1 415.9 544.4
GT13E2 202700 2262.92 38 624.1 501.1
(50 Hz)
Siemens

SGT5-2000E 172000 2434.03 35.3 531.2 536.7

SGT5-4000F 295000 2162.38 40 692.2 585.6
Ansaldo

GT26 326000 2133.65 40.3 692.2 602.8

(50 Hz)

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Power Output at ISO Conditions : LCV

Combined Cycle
Type of Open Cycle
Manufacturer Model (1 GT - 1 HRSG - 1 ST)
Machines Gross Output (MW)
Gross Output (MW)
9F 3-Series 261.3 397.1
9F 5-Series 298.2 454.1
GE 9F 7-Series 339.4 512.0
9HA.01 397.0 599.7
9HA.02 510.0 764.4
Advanced Class
SGT5-4000F 295.0 431.0
Machines Siemens
SGT5-8000H 375.0 570.0
M701F(4) 324.3 477.9
MHI M701G2 334.0 498.0
M701J 470.0 680.0
Ansaldo GT26 326.0 467.0
MS9001E 126.1 193.2
GE
Industrial Heavy GT13E2 202.7 281.0
Duty Machines Siemens SGT5-2000E 166.0 253.0
MHI M701DA 144.1 212.5

LCV denotes Lower Calorific Value of fuel

Source: GT World 2014-2015

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Thermal Efficiency at ISO Conditions : LCV

Open Cycle Thermal Combined Cycle Thermal
Manufacturer Model
Efficiency (%) Efficiency (%)

9F 3-Series 37.2 57.2

9F 5-Series 38.5 59.3
GE 9F 7-Series 39.9 61.0
9HA.01 41.5 61.6
9HA.02 41.8 61.8
SGT5-4000F 40.0 57.6
Siemens
SGT5-8000H 40.0 >60.0
M701F(4) 39.9 60.0
MHI M701G2 39.5 59.3
M701J 41.0 61.7
Ansaldo GT26 40.3 59.5
MS9001E 34.1 51.9
GE
GT13E2 38.0 53.5
Siemens SGT5-2000E 35.3 52.5
MHI M701DA 34.8 51.4

LCV denotes Lower Calorific Value of fuel

Source: GT World 2014-2015

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Gas Consumption, ISO Conditions

Combined Cycle
Manufacturer Model (1 GT-1 HRSG - 1 ST) Gas Consumption (MMSCMD)
Gross Output (MW)
9F 3-Series 397.1 1.79
9F 5-Series 454.1 1.97
GE 9F 7-Series 512.0 2.16
9HA.01 599.7 2.43
9HA.02 764.4 3.10
SGT5-4000F 431.0 1.88
Siemens
SGT5-8000H 570.0 2.39
M701F(4) 477.9 2.07
MHI M701G2 498.0 2.15
M701J 680.0 2.92
Ansaldo GT26 467.0 2.06
MS9001E 193.2 0.94
GE
GT13E2 281.0 1.36
Siemens SGT5-2000E 253.0 1.20
MHI M701DA 212.5 1.05

Source: GT World
1 MMSCMD : 1 million standard cubic meter per day

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SGT5-4000F adjustment to site conditions

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HEAT & MASS BALANCE DIAGRAM

Overall process flow diagram between the major equipment where
change in heat and flow mass takes place

WHAT HBD GIVES:

 Mass balance
 Heat balance
 Flow, pressure, temperature and enthalpy at various points in a cycle
during normal and abnormal conditions
 Overall plant performance & guarantee conditions

Purpose of Heat Balance Diagrams

 For preparation of FRs/DPRs
 For deciding design parameters for cycle equipment
 Pipe and valve sizing and design
 Initiate flow diagrams, process and instrumentation diagrams
 Checking performance of cycle
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HEAT & MASS BALANCE DIAGRAM

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BENEFIT OF GAS BASED CCPP

Efficiency / Heat Rate

Gas‐fired Combined Cycle Power Plants have better efficiency or

heat rate as compared to coal‐based plants.

The station heat rate for 210/250 MW Coal‐based power plant is

around 2460 kcal/kWh whereas, the same for a Combined Cycle
Plant is 1800 kcal/kWh.

The efficiency of Gas‐fired Combined Cycle Power Plant is rated

as 50 to 58% in comparison to 36 to 42% of Coal‐based power
plant.
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BENEFIT OF GAS BASED CCPP

Plant Development Time

The gestation period for establishing a Gas‐ fired Combined

Cycle Power Plant (400 MW) is about 24 months, whereas a
corresponding coal‐based station takes about 36 months.
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BENEFIT OF GAS BASED CCPP

Start-up Time

The normal start‐up time for cold conditions for a gas‐based

combined cycle plant and a coal‐based plant are 4 hours and 8
hours respectively.

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BENEFIT OF GAS BASED CCPP

Initial capital Investment

The initial investment required for a gas based combined cycle

power plant is MINR 30 to 35 per MW, whereas the same for a
coal‐based station is MINR 40 per MW.

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BENEFIT OF GAS BASED CCPP

Fuel Transportation Cost

There are no problems in natural gas transportation once the

pipelines are laid.

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BENEFIT OF GAS BASED CCPP

Space required

Space requirements for a gas‐based station is 0.3 to 0.5 acres

per MW, while for coal‐based stations the space requirement
varies from 1 to 1.5 acres per MW.

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BENEFIT OF GAS BASED CCPP

Water requirement

Consumptive water requirement is about 2.5 cubic meter per

MW in comparison to 3.5 to 5.0 cubic meter per MW in case of
coal‐based plants.

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BENEFIT OF GAS BASED CCPP

Environment Friendly

Gas shall be environmentally friendly fuel and should meet the

norms as specified.

Natural gas is often described as the cleanest fossil fuel. It

produces about
• 29% less carbon dioxide per joule delivered than oil
and
• 44% less carbon dioxide per joule delivered than coal.

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BENEFIT OF GAS BASED CCPP

Other Pollutants

Natural gas produces far lower amounts of Sulfur Dioxide and

Nitrous Oxides than any other hydrocarbon fuels.
The other pollutants due to natural gas combustion are listed
below in parts per million (ppm):
• Carbon Monoxide (CO) ‐ 40 ppm
• Sulfur Dioxide ‐ 1 ppm
• Nitrogen Oxide ‐ 92 ppm
• Particulates ‐ 7 ppm

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