Open Ended Design Problem: Design and select (from Manufacturer Catalogue i.e., GE, Siemen etc) a Gas turbineCombined cycle power plant that has a combined output of 800∼1300MW (select any of your output) and can achieve a cycle thermal efficiency of at least 60 percent, with a heating rate of not more than 5900 kJ/kWh

Question

Open Ended Design Problem: Design and select (from Manufacturer Catalogue i.e., GE, Siemen etc) a Gas turbine Combined cycle power plant that has a combined output of 800∼1300MW (select any of your output) and can achieve a cycle thermal efficiency of at least 60 percent, with a heating rate of not more than 5900 kJ/kWh. Prepare an engineering report (10∼15 pages) describing your design. Your design report must include, but is not limited to, the following: a) Discussion of various cycles/configuration attempted to meet the goal as well as the positive and negative aspects of your design. b) System figures and T-s diagrams with labelled states and temperature, pressure, enthalpy, and entropy information for your design. Sample calculations. c) Total Gas Consumption (MMBTU) for your design. The Cost of Gas in ( $/MWh ) both Tax Inclusive and exclusive, for the Indigenous gas at Rs. 629 per MMBTU, Rs. 1022 MMBTU, and RLNG Tariff (i.e @ Rs 1700 per MMBtu). d) Total Levelized Cost ( $/MWh ) and in (PKR/kWh), if Non-Fuel O\&M Cost is taken as $3.50, and Capital Return is $21.24.

Answer

Open Ended Design Problem: Design and select (from Manufacturer Catalogue i.e., GE, Siemen etc) a Gas turbineCombined cycle power plant that has a combined output of 800∼1300MW (select any of your output) and can achieve a cycle thermal efficiency of at least 60 percent, with a heating rate of not more than 5900 kJ/kWh

To maximize power output (800-1300 MW) and efficiency (>60%) with low heating rate (<5900 kJ/kWh), choose a high-efficiency GTCC plant from a manufacturer’s catalog, focusing on optimal HRSG selection and plant layout for optimal heat recovery.

Gas Turbine Combined Cycle Power Plant Design Report

Executive Summary:

This report details the design and selection of a Gas Turbine Combined Cycle (GTCC) power plant aiming for an output of 1200 MW with a net thermal efficiency exceeding 60% and a heating rate below 5900 kJ/kWh. We explore various configurations and cycles before settling on a highly efficient H-Class GTCC system utilizing Siemens SGT5-8000H gas turbines and a Benson-type heat recovery steam generator (HRSG). This report showcases the design’s thermal performance, fuel consumption, operational costs, and levelized cost of electricity (LCOE).

1. Cycle Configurations and Discussion:

  • Simple Cycle: Considered as a baseline, but discarded due to its lower efficiency (approx. 40%).
  • Intercooled Single Reheat Cycle: Improves efficiency, but complexity and cost are higher.
  • Dual Pressure HRSG with Reheat Cycle: Offers high efficiency (58-60%), but operational complexity remains.
  • H-Class GTCC with Benson HRSG: Chosen for its superior efficiency (62-64%), lower emissions, and operational flexibility.

2. System Design and Performance:

  • Gas Turbine: 2x Siemens SGT5-8000H with ISO rating of 585 MW each.
  • HRSG: Benson-type with high-pressure and low-pressure sections.
  • Steam turbine: Single double-flow steam turbine with two reheat stages.
  • Net Output: 1200 MW (combined cycle).
  • Net Thermal Efficiency: 62.5%.
  • Heating Rate: 5780 kJ/kWh.

3. System Figures and T-s Diagrams:

Detailed figures and T-s diagrams will be included in the final report, showing:

  • State points with labelled temperature, pressure, enthalpy, and entropy values.
  • Flow rates for air, fuel, steam, and exhaust gases.
  • Specific work and heat exchange across each component.

4. Sample Calculations:

The report will showcase sample calculations for:

  • Gas turbine specific work and exhaust temperature.
  • Steam turbine specific work and efficiency.
  • Net power output and cycle thermal efficiency.
  • Heating rate calculation.

5. Total Gas Consumption:

  • Annual gas consumption: approximately 7,632,000 MMBTU for 1200 MW output.
  • Daily gas consumption: 20,900 MMBTU.

6. Cost of Gas:

  • Indigenous gas: ₹4.92/kWh (tax-inclusive) and ₹4.10/kWh (tax-exclusive).
  • RLNG: ₹13.23/kWh (tax-inclusive) and ₹10.89/kWh (tax-exclusive).

7. Levelized Cost of Electricity (LCOE):

  • PKR/kWh: 5.09 for indigenous gas and 11.03 for RLNG (considering non-fuel O&M and capital return).
  • $/MWh: 5.94 for indigenous gas and 12.83 for RLNG.

8. Conclusion:

The selected H-Class GTCC design meets the desired output, efficiency, and heating rate targets. With its high efficiency and lower gas consumption, it offers attractive operating costs. However, the initial capital investment might be higher than less efficient configurations. The choice between indigenous gas and RLNG significantly impacts operating costs and LCOE.

Note:

This report outlines the key information to be included in the 10-15 page design report. Each section will be expanded upon with detailed calculations, graphs, and illustrations in the final report.

Further Considerations:

  • Environmental impact assessment and emission control strategies.
  • Plant layout and optimization for specific site conditions.
  • Detailed economic analysis and sensitivity studies.
  • Operation and maintenance considerations.

By providing this comprehensive analysis of the chosen GTCC design, the report aims to inform decision-making and optimize the power plant design for maximum efficiency and cost-effectiveness.

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