Energy Systems

School of Industrial Engineering - Master Mechanical Engineering

ACADEMIC YEAR 2014/15

Precept 4
Combined cycle: design of a Heat Recovery Steam Generator (HRSG)
The aim of this precept is to design a Heat Recovery Steam Generator for Combined Cycle power
plants. For question 1 and 2, the on-design performances of the selected gas turbine (GE Energy
Aeroderivative model LM6000PD sprint) at ISO (International Standard Organization) reference
conditions (15C, 1 atm) are listed in the following table.
ISO GT Performances
Electrical power
kW
Net electrical efficiency
%
Air mass flow rate
kg/s
Turbine outlet temperature
C
LHV of natural gas
MJ/kg

46900
41
133
445
45

QUESTION 1: design of a single pressure HRSG

The following design parameters are assigned:
Mechanical efficiency of steam turbine
Electrical efficiency of steam turbine
Steam turbine auxiliaries
Hydraulic efficiency of feedwater pump
Hydraulic efficiency of condenser extraction pump
Mechanical/electrical efficiency of pumps
Condensation pressure
Total auxiliary electric power consumption
Condensation electric power consumption
SH pressure drop (related to the inlet pressure)
ECO1 pressure drop (related to the inlet pressure)
ECO2 pressure drop (related to the inlet pressure)
T approach point
T pinch point
T subcooling
Evaporation pressure pEVA
Deaerator pressure
HRSG thermal losses
Isoentropic efficiency of steam turbine

= 99,5%
= 98,5%
= 0,5%
= 83%
= 85%
= 97,5%
= 0.05 bar
= 700 kW
= 4 kWh/t
= 7%
= 10%
= 10%
= 25C
= 10C
= 2C
= to be optimized (range [10 bar; 80 bar]
= 2 bar (no bleeding)
= 0.5%
= 91%

It is required:
a) to draw the combined cycle layout;
b) to calculate the optimized evaporator pressure, the maximum net electrical power and the
maximum net electrical efficiency of the combined cycle verifying the constraint on the minimum of
the temperature of the flue gases at stack outlet (80C);
c) to draw the T-Q diagram;
d) to calculate the heat recovery factor and the net electrical efficiency of the steam cycle

QUESTION 2: design of a two pressure levels HRSG with RH

The HRSG configuration, in the direction of the flue gases, from inlet to outlet, is as follows: high
pressure superheater (HP SH) in parallel with reheater (RH), high pressure evaporator (HP EVA),
second high pressure economizer (HP ECO2) in parallel with low pressure superheater (LP SH), low
pressure evaporator (LP EVA), low pressure economizer (LP ECO) in parallel with first high pressure
economizer (HP ECO1), and finally, deaerator and pre-heater. The steam turbine consists of three
sections: high, medium and low pressure. Steam from high pressure turbine enters the RH; medium
pressure steam from RH flows to medium pressure turbine and then it is mixed with the superheated
low pressure steam before it enters the low pressure turbine.
The following design parameters are assigned:
Mechanical efficiency of steam turbine
= 99,5%
Electrical efficiency of steam turbine
= 98,5%
Steam turbine auxiliaries
= 0,5%
Hydraulic efficiency of feedwater pump
= 83%
Hydraulic efficiency of condenser extraction pump
= 85%
Mechanical/electrical efficiency of pumps
= 97,5%
Condensation pressure
= 0.05 bar
Total auxiliary electric power consumption
= 700 kW
Condensation electric power consumption
= 4 kWh/t
HP SH pressure drop (related to the inlet pressure)
= 10%
RH pressure drop (related to the inlet pressure)
= 10%
HP ECO1 pressure drop (related to the inlet pressure) = 10%
HP ECO2 pressure drop (related to the inlet pressure) = 10%
LP SH pressure drop (related to the inlet pressure)
= 7%
LP ECO pressure drop (related to the inlet pressure) = 10%
PREHEAT pressure drop (related to the inlet pressure) = 10%
pEVA HP
= 80 bar
pEVA LP
= 8 bar
pRH
= 24 bar
Deaerator pressure
= 2 bar (no bleeding)
HRSG thermal losses
= 0.5%
Isoentropic efficiency of steam turbine
= 91%
It is required:
a) to draw the combined cycle layout;
b) to calculate the net electrical power and the net electrical efficiency of the combined cycle verifying
the constraint on the minimum stack outlet temperature of the flue gases (80C);
c) to draw the T-Q diagram;
d) to calculate the heat recovery factor and the net electrical efficiency of the steam cycle.
________________________________________________________________________________
For the calculation of specific heat of flue gases, cp, assume that it is expressed as a function of
temperature (T in [K]) and air/fuel ratio () as follows:
cp,FLUE GASES [kJ/kgK] = (0,8728+2,054*10-4 T) (1+1/)1.78

6
air

5
3
flue gases
gas turbine

steam
turbine

fuel
condenser
Figure 1 - Combined cycle power plant with single pressure HRSG.

air
10

11

RH

5 3
4

LP SH

HP SH

flue gases

EVA
HP

EVA
LP

gas turbine

HP ECO2

12

13
HP
AP

14
MP

steam
turbine

PRE
HEAT

LP ECO

8
HP ECO1

7
LP
BP

15

fuel
condenser
Figure 2 - Combined cycle power plant with two pressure levels HRSG with RH.