IMPROVING THE PERFORMANCE EFFICIENCY OF A GAS TURBINE

(SGT5-2000E)

BY

EBALUNOSE ONOSETALESE JOHN ENG1809200

AROGHO GODSTIME ORIGHO ENG1804565

SUPERVISED BY:

Dr PETER E. AKHATOR

A PROJECT WORK SUBMITTED TO THE DEPARTMENT OF MECHANICAL

ENGINEERING, FACULTY OF ENGINEERING UNIVERSITY OF BENIN,

BENIN CITY IN FULFILMENT OF THE REQUIREMENT FOR THE AWARD

OF BACHELOR OF ENGINEERING (B.Eng.) IN MECHANICAL

ENGINEERING

i
 OCTOBER, 2024

CERTIFICATION

This is to certify that the research project submitted to the Department of Mechanical

Engineering and Mechatronics Engineering and was carried out by EBALUNOSE

ONOSETALESE JOHN (ENG1809200) and AROGHO GODSTIME ORIGHOYE

(ENG1804565) of the Department of Mechanical Engineering, University of Benin.

_______________________

DR. PETER E. AKHATOR DATE

(Project Supervisor)

_______________________

PROF. E.G. SADJERE DATE

(Head of Department)

ii
iii
 DEDICATION

This project is dedicated to God almighty for His mercies and grace upon us and also to our

loving parents, family and friends for their love and care during our stay in the University of

Benin.

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 ACKNOWLEDGEMENT

First and foremost, we want to thank God Almighty for watching over us and guiding us

throughout our journey in this school, up till this very stage.

We would also like to express our sincere appreciation to Mr Oscar Imoekor, Mr David Ekugum,

Mr Femi Ogundaisi, Mrs Isuan Idonije and all those who have supported us in completing this

project.

Also, we are grateful to our wonderful supervisor, Dr Peter E. Akhator, for his guidance,

feedback, and encouragement throughout this project. We also thank classmates for their

valuable suggestions and constructive criticism.

Finally, we want to thank our families and friends for their moral support and understanding

during this challenging period. This project would not have been possible without the help of all

these people.

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 TABLE OF CONTENTS

CERTIFICATION

DEDICATION

ACKNOWLEDGEMENT

LIST OF FIGURES

LIST OF TABLES

NOMENCLATURE...........................................................................................................................x

ABSTRACT.....................................................................................................................................xi

CHAPTER ONE: iINTRODUCTION............................................................................................1

1.1 BACKGROUND TO THE STUDY............................................................................................1

1.2 STATEMENT OF THE PROBLEM..........................................................................................13

1.3 AIM AND OBJECTIVES OF THE RESEARCH.....................................................................15

1.3.1 AIMS OF THE RESEARCH:.................................................................................................15

1.3.2 OBJECTIVES OF THE RESEARCH:...................................................................................16

1.4 SCOPE OF THE RESEARCH..................................................................................................16

1.5 METHODOLOGY....................................................................................................................17

1.6 RELEVANCE OF THE STUDY...............................................................................................18

CHAPTER TWO: LITERATURE IN REVIEW...........................................................................19

2.0 GAS TURBINE.........................................................................................................................19

2.1 COMPONENTS OF A GAS TURBINE...................................................................................19

2.1.1 COMPRESSOR:.....................................................................................................................19

2.1.2 COMBUSTION SYSTEM:....................................................................................................20

2.1.3 TURBINE:..............................................................................................................................21

2.1.4 EXHAUST SYSTEM:............................................................................................................22

2.2 OVERVIEW OF A COMBINED CYCLE................................................................................23

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2.2.1 HEAT RECOVERY STEAM GENERATOR (HRSG)..........................................................24

2.2.2 STEAM TURBINE.................................................................................................................25

2.3 EARLY DEVELOPMENT........................................................................................................26

2.4 RECENT DEVELOPMENT.....................................................................................................27

2.4.1 EFFECTS OF AMBIENT CONDITIONS.............................................................................28

2.4.2 EFFECT OF PART LOAD CONDITIONS............................................................................30

2.5 REVISION ON PAST RELATED LITERATION ON METHODS OF INCREASING

THERMAL EFFICIENCY OF STEAM AND GAS TURBINE PLANTS.....................................31

2.6 TURBO EXPANDERS..............................................................................................................35

2.7 MODELLING SOFTWARE.....................................................................................................37

2.8 SUMMARY OF LITERATURE................................................................................................38

CHAPTER THREE: METHODOLOGY.....................................................................................40

3.1 DATA COLLECTION AND OVERVIEW OF AZURA EDO INDEPENDENT POWER

PLANT............................................................................................................................................40

3.2 THERMODYNAMIC OPERATIONAL PRINCIPLE OF COMBINED POWER PLANT

.........................................................................................................................................................41

3.3 MODELLING EQUATIONS....................................................................................................44

3.3.1 Combustion Chamber.............................................................................................................44

3.3.3 Compressor and Pump............................................................................................................46

3.3.4 Heat Exchanger.......................................................................................................................47

3.4 DESIGN / OFF-DESIGN MODE.............................................................................................48

3.5 MODELING AND SIMULATION WITH EBSILON PROFESSIONAL................................49

3.6 OPERATING PARAMETERS OF SGT5-2000E......................................................................51

3.6.1 MODELING OF THE GAS TURBINE BASED ON DESIGN CONDITION.....................53

3.6.2 OFF DESIGN MODELLING OF THE COMBINED CYCLE GAS TURBINE..................58

3.6.3 VARIATION OF AIR – FUEL RATIO...................................................................................59

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 3.6.4 VARIATION OF PART LOAD..............................................................................................62

3.7 VARIATION OF EFFICIENCY IN COMPONENTS...............................................................63

3.8 VALIDATION OF MODEL......................................................................................................64

3.9 COST ANALYSIS FOR INTEGRATING THE AZURA EDO POWER PLANT INTO A

COMBINED CYCLE PLANT………………………………………………………………......65

CHAPTER FOUR: RESULTS AND DISCUSSION....................................................................69

4.1 MODEL VALIDATION............................................................................................................69

4.2 AMBIENT TEMPERATURE VARIATION..............................................................................71

4.3 FUEL AND AIRFLOW VARIATION.......................................................................................74

CHAPTER FIVE: CONCLUSION AND RECOMMENDATION ..........................................77

5.1 CONCLUSION..........................................................................................................................77

5.2 RECOMMENDATIONS............................................................................................................78

REFERENCES................................................................................................................................80

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 LIST OF FIGURES

Figure 2.1 Gas Turbine 19

Figure 2.2 Combustion Chamber 21

Figure 2.3 Schematic diagram of a combined cycle (Edgar Torres et al, 2017) 24

Figure 2.4 Steam Turbine 26

Figure 2.5 Turboexpander 35

Figure 3.1 Gas Turbine Schematics 43

Figure 3.2 Simple Brayton cycle and Rankine cycle Ts diagram 43

Figure 3.3 Fluid Properties of the combustion area 44

Figure 3.4 Steam Turbine and Gas Turbine fluid properties 45

Figure 3.5 Fluid Properties of Pump and Compressor 46

Figure 3.6 Fluid properties of a heat exchanger 47

Figure 3.7 Design/ Off-design mode 50

Figure 3.9 SGT5-2000E gas turbine model 55

Figure 3.10 Combined Cycle Gas Turbine (Design Mode) 57

Figure 3.11 Combined Cycle Gas Turbine (75% of base load, off design mode) 61

Figure 3.12 Gas turbine operating in 60% part load conditions. 62

Figure 3.13 Sankey diagram of Azura Edo IPP with combined cycle 65

Figure 4.1. Model vs Actual performance 72

Figure 4.2. Model vs Actual performance 72

Figure 4.3. Inlet Temperature vs GT Power and ST Power at constant exhaust temperature 75

Figure 4.4. Inlet Temperature vs Air Ratio 75

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 LIST OF TABLES

Table 3.1 Guaranteed performance for SGT5-2000E..........................................................................53

Table 3.2 Performance Data for SGT5-2000E Off Design.................................................................58

Table 4.1 Results of Model validation for ISO Design Data...............................................................64

Table 3.3 Variation of Efficiency in compressor with mass flow........................................................68

Table 3.4 Variation of Efficiency in Gas Turbine with mass flow......................................................66

Table 3.5 The costs and financial benefits of converting the Azura Edo Independent Power Plant

from a simple cycle to a combined cycle operation............................................................................68

Table 4.1 Results of Model validation for ISO Design Data...............................................................69

.................................................................................................................................................................

.................................................................................................................................................................

.................................................................................................................................................................

.............................................................................................................................................................69

Table 4.2. Variation of Parameters in ambient temperature off-design...............................................71

Table 4.3. Model validation using operational data............................................................................73

Table 4.4. Variation of air fuel ratio with ambient temperature..........................................................74

x
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 NOMENCLATURE

M Mass

h Enthalpy

P Pressure

𝜂 Efficiency

𝑣 Specific volume

Q̇ 𝑅𝑎𝑑 Radiation losses

Q̇ Energy in watts

𝜌 Density

∅ Relative humidity

ETAI/ETAIN Variation in isentropic efficiency on compressor or turbine with regards to

isentropic efficiency in nominal conditions

P(GT) Power developed in the gas turbine P(ST) Power developed in the steam turbine T1

Ambient temperature

T2 Inlet temperature to combustion chamber

T3 Inlet temperature to turbine section

T4 Exhaust temperature from gas turbine

P3 Pressure at entry to turbine section of the gas turbine

xii
 ABSTRACT
This research project underscores the significance of computer engineering software for
modeling and simulating complex systems, exemplified by the SGT5-2000E combined cycle gas
turbine using EBSILON PROFESSIONAL. The study involved modeling the design mode with
guaranteed performance data from the power plant and exploring off-design scenarios
incorporating temperature variations of ambient air and fogging (spray water at compressor
inlet).
The fogging simulation encompassed two modes: one with constant fuel consumption and
another with constant turbine exhaust temperature. Validation of the model results was
performed using actual operating data through error percentage analysis, yielding validation
results ranging from -0.0038% to 0% under design conditions and -0.9202% to 10.24% under
off-design conditions.
Key conclusions drawn from the research include; as ambient temperature increases, the mass
flow rate of air decreases, consequently reducing the power output of the gas turbine. This
temperature effect also diminishes the energy available in the flue gas, thereby reducing power
output in the steam turbine and overall cycle efficiency.
To maintain the design exhaust temperature, additional fuel must be burned to sustain the
combustion process effectively. Additionally, findings from the simulation indicates that
increasing the mass flow rate results in increased power generation in the steam turbine.
However, the HRSG's sensitivity to heat imposes limitations on the amount of solar steam that
can be added (capped at 3 kg/s). Exceeding this threshold risks issues within critical HRSG
components, particularly the evaporator, where insufficient energy could lead to steam
generation failure, compromising the entire steam cycle.
These insights highlight the intricate dynamics and operational constraints inherent in gas turbine
combined cycle systems, emphasizing the value of modeling and simulation tools for optimizing
performance and guiding operational decisions in power plant design and management.

xiii
 CHAPTER ONE

INTRODUCTION

1.1 BACKGROUND TO THE STUDY

In an era where global energy consumption continues its relentless ascent, the significance of

improving the efficiency of gas turbines cannot be overstated. Gas turbines serve as

indispensable workhorses across a multitude of sectors, including power generation, aviation,

and industrial processes, by virtue of their remarkable power-to-weight ratios and operational

flexibility. However, in this age of burgeoning energy demands, a collective call to action

emerges - a call to harness the full potential of gas turbines, to refine and advance their

capabilities, and to unlock the key to optimizing their efficiency. (Saravanamuttoo et al 2001)

This report embarks on a comprehensive journey into the heart of gas turbine technology and its

multifaceted realm, with a resolute focus on the paramount aim of improving efficiency to new

heights. The report does not merely seek to skim the surface of this intricate subject, but rather,

aims to plunge into the depths of gas turbine theory, practice, and innovation. It's an exploration

that traverses the critical components of these mechanical marvels - the compressors,

combustion chambers, and turbines - each an integral cog in the intricate machinery of gas

turbines, and each holding the potential to either impede or augment overall efficiency.

The report ventures into the cutting-edge landscape of technological advancements that have

revolutionized the gas turbine domain. Advanced materials, adorned with thermal barrier

coatings, are explored for their role in augmenting durability and efficiency. (Wang, T et al

2016). Meanwhile, advancements in aerodynamics and combustion technologies are unveiled,

unveiling the secrets of heightened power output and minimized emissions. The digital realm is

not forgotten, with digitalization and control systems taking center stage, providing a gateway to

optimized operation and predictive maintenance techniques.

But this journey doesn't stop with technology alone; it ventures into operational strategies as

well. Combined cycle power plants, which ingeniously unite gas turbines with steam turbines
1
offer a transformative route to improved overall efficiency. Likewise, the meticulous

management of load and grid integration is addressed, where the art of achieving part-load

efficiency and seamless grid interaction is laid bare.

Delving deeper, the profound environmental impact of these endeavors becomes ever more

apparent. Emissions reduction emerges as a key facet, offering us the opportunity to mitigate our

ecological footprint by enhancing gas turbine efficiency. Simultaneously, we confront the

regulatory landscape and sustainability goals that shape the path forward.

The report is not only about theory - it's about reality, with a wealth of case studies painting a

vivid picture of successful gas turbine efficiency enhancement projects. These real-world

examples will serve as beacons of inspiration and knowledge for those on similar journeys.

Concluding this report, we offer you a set of key findings and recommendations, distilled from

this extensive exploration. These findings provide insights into the current state of gas turbine

technology, while the recommendations chart a course for policymakers, manufacturers, and

operators to navigate toward more efficient and sustainable energy generation. (Welch Michael

et al 2015).

And so, this report embarks on a journey through the dynamic world of gas turbines, providing

an in-depth understanding of the complex components, the latest innovations, and the

strategies that collectively drive the perpetual pursuit of improved gas turbine efficiency,

ultimately fostering a more sustainable and energy-efficient future. (Welch Michael 2016).

1.2 STATEMENT OF THE PROBLEM

The quest of improving gas turbine efficiency presents a multifaceted challenge within the

energy sector. Gas turbines, versatile and ubiquitous in their applications, grapple with several

intricate problems that hinder their performance and sustainability. These issues span various

key problem areas, necessitating comprehensive attention and innovation.

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Firstly, inherent energy losses represent a fundamental challenge. Gas turbines exhibit losses

throughout their operational cycle, manifesting as dissipated heat, mechanical inefficiencies,

and aerodynamic drawbacks. These energy losses significantly compromise overall

efficiency, leading to heightened fuel consumption and increased operational costs.

Furthermore, the environmental impact of gas turbines is a pressing concern. Like other

fossil fuel-based technologies, gas turbines emit greenhouse gases and pollutants such as

nitrogen oxides (NOx). Mitigating these emissions while simultaneously enhancing

efficiency is a formidable task, especially in the face of stringent environmental regulations

and the imperative drive towards sustainability. (Oyedepo et al 2015)

The integration of gas turbines with intermittent renewable energy sources, such as wind and

solar power, introduces variability into power supply. Gas turbines must respond rapidly to

these fluctuations to maintain grid stability. Balancing efficiency with the accommodation of

variable load demands poses an operational and engineering challenge.

Aging infrastructure represents another facet of the problem. Many existing gas turbine

power plants have aged, and their components may be deteriorating. Extending the

operational life of these facilities while ensuring efficient operation necessitates effective

maintenance and refurbishment practices.

Fuel flexibility is a crucial issue in the pursuit of improved gas turbine efficiency. Traditional

gas turbines are often optimized for specific fuel types. Adapting gas turbines to a broader

range of fuels, including alternative and renewable sources, presents a formidable challenge,

but it is essential to achieve energy diversity and sustainability.

Inefficient part-load operation is a persistent problem in gas turbine operation. Gas turbines

often operate at partial loads, especially in grid-balancing scenarios. Maintaining high

efficiency under these conditions is challenging, as gas turbines are typically optimized for

14
full-load operation.

Developing efficient cooling technologies that minimize water usage while optimizing gas

turbine performance is of utmost importance.

The underutilization of waste heat generated during gas turbine operation is a problem that

warrants attention. Efficiently capturing and using this waste heat for processes like

cogeneration, combined cycle applications, or other industrial processes holds the potential

for substantial efficiency improvements and resource utilization. (Wang, T et al 2016).

Addressing these complex issues is pivotal in the advancement of gas turbine technology and

the realization of a sustainable and energy-efficient future. Innovative strategies, advanced

materials, and operational practices are vital to enhancing gas turbine efficiency, reducing

environmental impacts, and ensuring energy security.

1.3 AIM AND OBJECTIVES OF THE RESEARCH

1.3.1 Aims of the Research:

I. The research aims to provide a thorough exploration of gas turbine technology, going

beyond surface-level understanding and delving into its intricate components, theory,

practice, and innovation.

II. The primary goal is to unlock the full potential of gas turbines, refining and advancing

their capabilities to achieve new heights of efficiency.

III. The research focuses on investigating cutting-edge technological advancements,

including advanced materials, aerodynamics, combustion technologies, and digitalization,

to identify their roles in enhancing efficiency.

IV. Exploration of operational strategies such as combined cycle power plants and load/grid

management as potential routes to improved overall efficiency.

V. Consideration of the profound environmental impact of these endeavors, with a specific

emphasis on emissions reduction.

15
VI. Incorporation of real-world case studies to provide practical examples of successful gas

turbine efficiency enhancement projects, offering insights and inspiration.

1.3.2 Objectives of the Research

I. Investigate the critical components of gas turbines, including compressors, combustion

chambers, and turbines, to understand their role in overall efficiency.

II. Assess the impact of advanced materials, thermal barrier coatings, aerodynamics,

combustion technologies, and digitalization on gas turbine efficiency.

III. Evaluate the effectiveness of operational strategies such as combined cycle power plants,

load management, and grid integration in improving overall efficiency.

IV. Examine strategies for reducing emissions and mitigating the environmental footprint

associated with gas turbine operation.

V. Analyze real-world case studies to extract lessons and insights for successful gas turbine

efficiency enhancement projects.

VI. Distill key findings and provide recommendations based on the research insights to guide

policymakers, manufacturers, and operators toward more efficient and sustainable energy

generation.

1.4 SCOPE OF THE RESEARCH

The research covers;

i. Efficiency enhancement of Gas Turbine Systems with air injection driven by Natural

Gas Turboexpanders.

ii. Power enhancement method by inlet air cooling and by using outlet hot gas.

iii. Integrating the SGT5 2000E into a combined cycle power plant, where waste heat is

utilized by a steam turbine.

iv. Optimizing gas turbine operation by efficiently managing load fluctuations and

16
integrating with the grid. Load-following strategies, grid stabilization, and frequency

control ensuring the SGT5 2000E operates at peak efficiency under varying conditions.

v. Implementing emission control technologies, such as selective catalytic reduction

(SCR) and dry low-NOx combustion systems, to reduce emissions while maintaining

high efficiency.

vii. Causes and effects of gas turbine degradation.

1.5 METHODOLOGY

The research methods adopted in this work include:

I. A review of pertinent literature

II. Overview of the Siemens SGT5 2000E Gas Turbine.

III. Performance metrics from gas turbine systems utilizing air injection driven by natural gas

turboexpanders.

IV. Analysis on power enhancement techniques involving inlet air cooling and utilizing

outlet hot gas.

V. Investigating advanced materials and coatings suitable for gas turbine components.

Evaluating their potential for enhancing durability, performance, and efficiency through

material property analysis and compatibility studies.

VI. Analyzing the integration of the SGT5 2000E into combined cycle power plants. Collect

data on waste heat utilization by steam turbines and assess the overall efficiency gains

achieved through this integration.

VII. Analysing operational data under varying load conditions. Analyze load-following

strategies, grid integration methods, and frequency control mechanisms. Evaluate their

impact on SGT5 2000E performance and efficiency.

VIII. Analysis of emissions data from gas turbines equipped with SCR and dry low-NOx

combustion systems. Analyzing the effectiveness of these technologies in reducing

17
emissions while maintaining high efficiency using Azura Edo Independent Power Plant

as case study.

IX. Investigating causes and effects of gas turbine degradation through field data analysis and

degradation modeling. Identify degradation mechanisms impacting efficiency and

operational lifespan.

X. Optimizing operational parameters based on data analysis and experimental findings to

maximize efficiency gains.

1.6 RELEVANCE OF THE STUDY

Research aimed at enhancing the efficiency of the SGT5 2000E gas turbine through various

methodologies hold significant relevance across multiple domains. It directly addresses

pressing energy sector concerns by reducing fuel consumption, fostering cost-effectiveness,

and bolstering energy sustainability. Moreover, the integration of emission reduction

technologies aligns with global efforts to mitigate environmental impacts and combat climate

change.

Technological innovations such as advanced materials and coatings contribute to the

evolution of turbine design, while optimization strategies for grid stability and load

management ensure a seamless integration with renewable energy sources. Additionally, the

research's emphasis on waste heat utilization and degradation analysis offers pathways for

resource optimization, maintenance improvement, and scientific advancements. Collectively,

this research not only propels industrial competitiveness but also contributes to sustainable

development goals, scientific knowledge enhancement, and a more resilient and efficient

global energy landscape

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 CHAPTER TWO

LITERATURE IN REVIEW

2.0 GAS TURBINE

A gas turbine, also known as a combustion turbine, is a type of internal combustion engine

that converts chemical energy from fuel into mechanical energy in the form of rotational

motion. It operates on the principle of continuous combustion, where air is compressed,

mixed with fuel, and then ignited to produce a high-velocity stream of hot gases. These gases

are expelled through a series of turbine blades, causing them to spin. This rotational motion is

used to drive various applications, such as generating electricity in power plants, powering

aircraft engines, or driving industrial machinery. Gas turbines are known for their high

power-to-weight ratio, efficiency, and versatility in various applications. H.I.H.

Saravanamuttoo et al (2016)

Figure 2.1 Gas Turbine

2.1 COMPONENTS OF A GAS TURBINE

2.1.1 Compressor:

Air is drawn into the gas turbine through the inlet. Filters may be present to remove

contaminants.

The compressor raises the pressure of the incoming air. It typically consists of multiple axial

or centrifugal compressor stages. The compression section of a gas turbine is a critical

component responsible for raising the pressure of the incoming air before it enters the

19
combustion chamber. The compressor has 0-16 stages including the IGV (inlet guide vane)

which controls the amount of air that enters the compressor. The gas turbine has a compressor

ratio of 13.

2.1.2 Combustion System:

Combustor or Combustion Chamber:

The compressed air from the compressor is mixed with fuel and ignited in the combustion

chamber. The combustion process produces high-temperature, high-pressure gases. The

combustion chamber of a gas turbine is a critical component where fuel is mixed with

compressed air and ignited to generate high-temperature, high-pressure gases. These gases

then expand through the turbine, driving it and ultimately producing power. The design of the

combustion chamber is essential for efficient and clean combustion, as well as for controlling

emissions and maintaining engine performance.

A double silo combustion chamber, also known as a dual-silo combustion chamber, is a

specific design used in certain industrial gas turbines. This configuration consists of two

separate combustion chambers or silos arranged in parallel within the gas turbine engine.

Each silo typically has its own set of fuel injectors and flame stabilization mechanisms.

The primary purpose of a double silo combustion chamber is to enhance combustion stability

and operational flexibility. It allows for better control of combustion under various operating

conditions, such as load changes and fuel quality variations. By having two separate

combustion chambers, the gas turbine can adjust the combustion process in one silo while the

other continues to operate, ensuring a smoother and more reliable performance.

Additionally, the double silo design can contribute to emissions reduction and improved

efficiency, as it provides more control over the combustion process, allowing for optimized

fuel-air mixing and combustion. This is particularly important in industrial applications

where emissions regulations are stringent, and efficient energy conversion is crucial.

20
The specific design and implementation of double silo combustion chambers can vary among

different gas turbine manufacturers and models, but their common goal is to provide greater

operational flexibility, stability, and performance in industrial applications.

Figure 2.2 Combustion Chamber

There are two different burners in the combustion chamber namely:

⦁ Diffusion burner: where fuel and combustion air are mixed in the combustion, the mixing

and reaction happen at the same time. The combustion is controlled by the mixing, which has

a long yellow burning flame. This produces high temperatures in the combustion zone

resulting in high NOx level.

The diffusion burner is used during start up, for about 15 minutes and cuts off.

⦁ Premix burner: fuel and combustion air are mixed homogeneously inside the burner, the

mixing and reaction are separated. The combustion is controlled by the chemical reaction,

producing short blue flame. Lower heat temperatures are emitted, resulting in low NOx

levels.

2.1.3 Turbine:

The turbine section of a gas turbine is a crucial component responsible for extracting energy

from the high-temperature, high-pressure gases generated in the combustion chamber. The

21
SGT5 2000E has a Power output rating of 198MW, a frequency of 50Hz, a gr The turbine has

4 stages. It typically consists of two main parts:

High-Pressure Turbine (HPT): This is the first stage of the turbine section and is directly

connected to the compressor section. It receives the hot gases from the combustion chamber

and uses their energy to drive the high-pressure compressor. The HPT operates at higher

temperatures and pressures compared to the low-pressure turbine (LPT) downstream.

Low-Pressure Turbine (LPT): The low-pressure turbine is the second stage of the turbine

section. After the gases have passed through the high-pressure turbine, they enter the LPT,

where the remaining energy is extracted. The LPT is typically larger in diameter and operates

at lower temperatures and pressures compared to the HPT.

The primary function of the turbine section is to convert the kinetic energy of the hot gases

into mechanical energy, which is used to drive the compressor and any other connected

equipment, such as electrical generators in power generation applications or the fan in aircraft

engines. The efficiency and performance of the turbine section are critical to the overall

efficiency and power output of the gas turbine engine.

2.1.4 Exhaust System:

The exhaust of a gas turbine refers to the gases that exit the turbine section of the engine after

the energy has been extracted from them to produce mechanical work. The exhaust gases are

typically expelled at high velocity and temperature. A diffuser is connected to the turbine

outlet where the contaminant within the exhaust is minimized to prevent hazardous waste

from entering the atmosphere.

⦁ Pollution Control: The diffuser helps control and reduce the emission of contaminants and

hazardous substances that may be present in the exhaust gases. It accomplishes this by

promoting mixing and dilution of the exhaust gases with ambient air, which can reduce the

concentration of pollutants

22
⦁ Dispersal: It aids in dispersing the exhaust gases in a controlled manner, through the

exhaust stack ensuring that they are released into the atmosphere at a safe height and location.

This helps prevent ground-level pollution and minimizes the risk of exposure to hazardous

emissions

⦁ Noise Reduction: Depending on the design, a diffuser can contribute to reducing the noise

generated by the exhaust gases as they exit the turbine. This can be important in

environments where noise pollution is a concern.

2.2 OVERVIEW OF A COMBINED CYCLE

A combined cycle, characterized by a topping cycle operating at a higher maximum

temperature and a bottoming cycle at a lower maximum temperature, is a synergistic

integration of two thermodynamic cycles designed to enhance overall efficiency. In the

context of a combined cycle gas turbine, the topping cycle is represented by the Brayton

cycle, while the bottoming cycle is implemented as the Rankine cycle (Ibrahim and Rahman,

2011). The Brayton cycle expels heat at a temperature conducive for utilization as the energy

source for the Rankine cycle, owing to its elevated source temperature. As highlighted by

Saravamutto et al. (2009), the working fluid for the Rankine cycle involves steam or water,

whereas the working fluid for the Brayton cycle is air.

The combustion chamber of the gas turbine utilizes liquid or natural gas combustion to

generate a consistent pressure, propelling the turbine or rotor connected to the generator, thus

producing electricity. The residual heat from the exhaust of the gas turbine is recuperated and

employed in the heat recovery steam generator to generate superheated steam. This steam, in

turn, powers a steam turbine, driving another generator in the process.

23
Figure 2.3 Schematic diagram of a combined cycle (Edgar Torres et al, 2017)

2.2.1 Heat Recovery Steam Generator (Hrsg)

Heat Recovery Steam Generator (HRSG) Heat Recovery Steam Generators, commonly

known as HRSGs, consist of four primary components: economizer, evaporator, superheater,

and water preheater. HRSGs can be categorized based on two key factors:

Exhaust Gas Flow:

 Vertical: In this configuration, gas flows vertically over horizontal tubes.

 Horizontal: Horizontal HRSGs have gas moving horizontally over vertical tubes.

Pressure:

 Single Pressure: These HRSGs feature a single steam drum.

 Multi-pressure: Multi-pressure HRSGs, on the other hand, include two or three steam

drums. They comprise low, intermediate, and high-pressure sections, each equipped

with a steam drum and evaporator. Steam passes through superheaters to elevate its

temperature.
24
Certain HRSGs incorporate additional burners known as supplemental or duct firing. These

burners introduce extra energy, generating additional steam to enhance the output of the

steam turbine, often at a more economical cost. This is particularly useful during peak

electricity demands. HRSGs may also incorporate diverter valves to manage gas turbine input

in scenarios where there is no steam demand or when the HRSG requires maintenance.

2.2.2 Steam Turbine

The steam turbine, a distinctive heat engine, achieves substantial improvements in

thermodynamic efficiency by employing a unique strategy: utilizing multiple stages during

the expansion of steam. This multi-stage design enables the steam turbine to closely

approximate the ideal reversible expansion process, thereby optimizing its overall

performance.

A noteworthy advantage of the steam turbine lies in its capability to convert heat energy into

rotary motion. When connected to a generator, this rotary motion can be utilized to generate

electricity. These integrated systems, known as turbogenerators, serve as the fundamental

components of thermal power stations. These power stations can draw energy from various

sources, including fossil fuels, nuclear fuels, geothermal energy, or solar energy.

However, the application of steam turbines presents technical challenges. These challenges

encompass addressing issues such as rotor imbalance, vibrations, wear and tear on bearings,

and managing uneven expansion, which may result in various forms of thermal shock. In

larger installations, even robust turbines may encounter problems if they operate beyond their

optimal conditions, potentially leading to mechanical issues or structural damage.

Consequently, meticulous engineering and maintenance are imperative to ensure the reliable

and efficient operation of steam turbines in power generation systems.

25
Figure 2.4 Steam Turbine

2.3 EARLY DEVELOPMENT

The majority of coal-fired and natural gas-fueled power cycles during the early stages

exhibited efficiencies within the 30% range. Consequently, a significant portion of the heat

energy from the combustion process was released into the atmosphere as waste. The

breakthrough in utilizing this substantial waste heat from gas turbines occurred at the

Korneuburg-A plant in Austria in 1961. This power plant featured two 25MW Brown Boveri

& Cie steam turbines, achieving an overall efficiency of approximately 32.5%. While this

marked a modest improvement from the standard 30% efficiency at the time, the success of

the Korneuburg-A plant validated the viability of this concept (Daniel Green et al, 2021).

The pivotal element enabling this efficiency improvement in combined cycles is the Heat

Recovery Steam Generator (HRSG), functioning as a heat exchanger. The HRSG facilitates

the transfer of heat from the hot flue gas, originating from the gas turbine exhaust, to water.

In his study on low power combined cycles, El-Wakil (1984) found that the power output

from the steam turbine was about 50% lower than that from the gas turbine. The cycle

typically includes a deaerator and closed feedwater heater as additional components. To meet

26
peak electricity demands during specific hours, supplementary fuel burning can temporarily

boost power output.

Despite sacrificing the inherent compactness of gas turbines found in binary cycle plants,

combined cycles offer significantly higher efficiency compared to simple cycles.

Consequently, they have become widely adopted for large-scale electricity generation

(Saravanamutto et al., 2009; Ighodaro and Aburine, 2011).

Early Combined Cycle Power Plants (CCPP) faced performance limitations, attributed to

several factors:

 Steam turbines were not optimized for combined cycle operations during that period.

They might have been adapted from existing designs for different applications,

lacking effective harnessing of waste heat from gas turbines.

 Gas turbines, as used in the Korneuburg-A plant, were based on early designs

characterized by lower compression ratios and less advanced combustion technology.

These limitations resulted in lower thermal efficiencies, hindering the extraction of

maximum energy from the fuel.

 Early combined cycle power plants encountered challenges in fully integrating gas

and steam cycles due to less sophisticated engineering and technology for efficient

heat recovery and transfer.

2.4 RECENT DEVELOPMENT

Recent developments in the energy sector underscore the growing significance of combined

cycle power plants (CCPPs) in global electricity production. The primary objective of these

power plants is to enhance efficiency and explore the intricate relationship between efficiency

and electricity expenses. However, the environmental repercussions associated with burning

fossil fuels for electricity generation, such as ozone layer depletion, global warming, and air

pollution, have raised concerns globally. In response, there is a growing emphasis on

27
transitioning to clean and renewable energy sources like solar and wind to mitigate the

adverse effects of fossil fuel-based electricity generation. An alternative approach involves

the reorganization of existing fossil fuel power plants to enhance generation efficiency and

reduce greenhouse gas emissions (Xiaoli et al., 2022).

Despite the push towards renewable energy, only about 23% of the world's generation

capacity is currently derived from clean and renewable sources, highlighting the continued

dominance of fossil fuel-based power plants (IRENA 2022). Given this reality, there is a

critical need to revamp fossil fuel power plants to improve their thermal efficiency and

overall power generation capabilities.

Notably, CCPPs exhibit high capacity and comparatively low emissions, generating 32%

waste and 68% electricity. In contrast, other types of power plants can only produce 33%

electricity (Niu and Liu, 2008). These advantages underscore the importance of CCPPs in the

evolving energy landscape, leading to increased attention to power plant forecasting models

for prediction and interpretation among researchers.

Accurate prediction of a power plant's output requires a comprehensive understanding of the

influencing factors and their interplay. The goal is not only to maximize income from

available megawatt hours (MW/h) but also to establish highly efficient, reliable, and

sustainable power plants. As CCPP usage continues to rise, the development of sophisticated

forecasting models becomes imperative for optimizing operational outcomes in the evolving

energy paradigm.

2.4.1 EFFECTS OF AMBIENT CONDITIONS

Ambient conditions, encompassing ambient temperature (AT), atmospheric pressure (AP),

relative humidity (RH), turbine inlet temperature (TIT), and exhaust steam pressure (also

referred to as vacuum, V), play a crucial role in influencing the performance of Combined

Cycle Power Plants (CCPP).

28
Benin City, Nigeria, typically experiences an average ambient temperature ranging from

24°C to 29°C throughout the year. This temperature range is significantly higher than the

ambient design condition of 23°C for the SGT5-2000E Gas Turbine.

The efficiency and performance of gas turbines are highly sensitive to ambient temperature.

When the ambient temperature rises above the design condition, the air density decreases,

leading to a reduction in the mass flow rate of air entering the turbine. Consequently, the

power output and efficiency of the turbine diminish. For the SGT5-2000E Gas Turbine,

operating in Benin City's higher ambient temperatures will result in a decrease in thermal

efficiency and power output compared to its performance at the optimal 23°C design

condition.

To mitigate these effects, various cooling techniques, such as evaporative cooling or inlet air

chilling, can be employed to lower the intake air temperature, thereby improving the turbine's

performance under the hotter ambient conditions prevalent in Benin City.

The electrical power generated by the gas and steam turbines serves as the system's target

variable, with these ambient parameters serving as input variables (Tüfekci, 2014).

Thamir et al. (2013) emphasized that ambient temperature, compression ratio, and turbine

inlet temperature collectively impact the overall performance of a combined cycle gas

turbine. These variables influence power output, heat rate, and overall thermal efficiency.

Utilizing THERMOFLEX software, the study created a thermodynamic model for an actual

combined cycle gas turbine. The results indicated that an increase in ambient temperature led

to a decrease in the overall efficiency and power output of a combined cycle gas turbine. This

is attributed to the increased power required by the gas turbine's air compressor under higher

ambient temperatures. While the overall efficiency of a combined cycle gas turbine rises with

an increase in compression ratio up to 21, beyond this point, the total power of the combined

cycle decreases as the compression ratio continues to increase.

29
2.4.2 EFFECT OF PART LOAD CONDITIONS

The operational dynamics of gas turbines, often characterized by significant periods of part-

load conditions throughout their operational life, necessitate a comprehensive consideration

of off-design performance alongside their design efficiency. Power reduction inherently leads

to a decline in performance, irrespective of the gas turbine's specific configuration. To

enhance overall fuel economy, meticulous attention must be directed towards improving part-

load performance.

A notable contribution to this endeavor is the intermediate recuperated combined cycle gas

turbine (IRCCGT) system, as explored by Yongyi et al. in 2020. This innovative system

aimed to bolster the performance of combined cycle gas turbines (CCGT) under part-load

conditions. The design objective was to prevent the turbine inlet temperature (TIT) from

decreasing as the load is reduced. A heat exchanger between the third and fourth turbine

stages facilitated the heating of compressed air using the exhaust from the third turbine stage.

The study revealed that, by implementing this system, the TIT could be maintained at the

designed value until the gas turbine part load was reduced to 49%. Interestingly, the

recuperative mass flow rate had a minimal impact on system performance, while the pressure

drop in the recuperator exhibited a significant influence.

In 2009, Miroslav examined part-load conditions in an 80 MW combined cycle power plant

in Slovakia to identify potential fuel-saving strategies. Analysis of the plant's online

monitoring data identified three potential solutions: condensate preheating by activating the

currently idle hot water section, adjusting the steam condensing pressure regulation strategy,

and crucially, gas turbine inlet air preheating. Contrary to common expectations, higher inlet

air temperatures did not negatively impact gas turbines operating at part load. Instead, they

led to an increase in high-pressure steam in the heat recovery steam generator (HRSG),

subsequently enhancing the power output of the steam turbine and necessitating less fuel in

30
the combustion chamber to produce the same power output. The study suggested that

implementing all three recommendations simultaneously could potentially reduce the power

plant's fuel consumption by 2%, albeit with a modest initial capital cost.

These research findings underscore the significance of addressing part-load performance in

gas turbines and highlight innovative solutions that not only enhance efficiency but also

contribute to notable fuel savings, emphasizing the importance of ongoing research and

development in the field of gas turbine technology.

2.5 REVISION ON PAST RELATED LITERATION ON METHODS OF

INCREASING THERMAL EFFICIENCY OF STEAM OND GAS TURBINE PLANTS

Welch et al (2015), explored strategies for improving the flexibility and efficiency of gas

turbine-based distributed power plants. The examined the concept of flexibility in the context

of gas turbine-based distributed power plants, emphasizing the importance of flexibility in

meeting dynamic energy demands and grid requirements. Delving into advanced control

strategies, grid synchronization mechanisms, and load-following capabilities that enhance the

overall flexibility of gas turbine systems. This section of the review aims to provide a

comprehensive understanding of the challenges associated with achieving flexibility and the

innovative solutions proposed by the authors.

Efficiency Improvements:

The review then focuses on efficiency enhancements in gas turbine-based distributed power

plants, drawing on Welch and Pym's insights. The authors discuss technological

advancements and operational strategies aimed at maximizing the overall efficiency of gas

turbines. This includes the exploration of advanced materials, combustion technologies, and

heat recovery methods. The review will highlight key findings related to the optimization of

the thermodynamic cycle, combustion stability, and the integration of waste heat recovery

systems.

31
Advanced Control and Monitoring Systems:

Welch and Pym's presentation emphasizes the role of advanced control and monitoring

systems in achieving superior performance in distributed power plants. The literature review

will explore the implementation of state-of-the-art control algorithms, predictive maintenance

techniques, and real-time monitoring solutions. Insights into the integration of digital

technologies, such as Industrial Internet of Things (IIoT), for condition-based maintenance

and performance optimization will be discussed. This section aims to provide a

comprehensive overview of the role of modern control and monitoring systems in enhancing

the reliability and availability of gas turbine-based distributed power plants.

Operational Challenges and Solutions:

The review will also address operational challenges encountered in the field of gas turbine-

based distributed power generation, as outlined by Welch and Pym. This includes

considerations related to transient operations, part-load efficiency, and start-up/shutdown

procedures. The literature review aims to summarize the proposed solutions and

technological innovations presented by the authors to mitigate these challenges and ensure

optimal performance under varying operating conditions.

Conclusion:

In conclusion, Welch et al (2015) from Siemens Industrial Turbomachinery Ltd., have made

significant contributions to the discourse on improving the flexibility and efficiency of gas

turbine-based distributed power plants. This literature review provides a comprehensive

synthesis of their insights, covering key aspects such as flexibility enhancements, efficiency

improvements, advanced control and monitoring systems, and solutions to operational

challenges. By understanding and building upon these advancements, researchers and

industry professionals can contribute to the ongoing evolution of distributed power

generation systems, addressing the dynamic needs of the modern energy landscape.

32
Efficiency of gas turbine power plant with regenerative heat exchange may be increased if

regeneration of the heat will be between gases after high pressure turbine and air after

compressor. This will increase temperature of air entering combustion chamber with

corresponding increase of average temperature of heat supply. Average temperature of heat

removal will be decreased because temperatures of gases after expansion in the low pressure

turbine will be lower than their temperature at regenerative heat exchanger outlet in

conventional cycle. Vasserman A A et al (2003)

Essence of the method is exhibited the conventional and modified regenerative cycles of gas

turbine plants in T,s coordinates. Schemes of gas turbine plant WR-21 and modified plant

with high temperature heat exchange

33
Schemes of conventional - a) and modified - b) gas turbine plants. LPC – low pressure

compressor, IC – intercooler, HPC – high pressure compressor, RHE – regenerative heat

exchanger, CC – combustion chamber, HPT – high pressure turbine, LPT – low pressure

turbine

Increase of thermodynamic efficiency will be observed if following condition is met:

L  L L
 0

34
 Q1  Q1 Q1

Above equation is always fulfilled if relative efficiencies of turbines and combustion chamber

are ignored, i.e. thermodynamic efficiency is increasing for all values of pressure ratio and

maximum temperature at high pressure turbine inlet which are typical for modern gas turbine

plants. So for practical purposes we may consider that thermodynamic efficiency is always

increasing. Vasserman A A and Shutenko M A (2004).

2.6 TURBO EXPANDERS

Gas turboexpanders, also known as expansion turbines, play a crucial role in recovering

process energy within natural gas facilities and refineries, mitigating typical energy losses.

Turboexpanders find diverse applications, with this document primarily focusing on their role

in energy recovery and power generation. Virtually any high enthalpy gas, characterized by

temperature and pressure, stands as a potential candidate for energy recovery. Custom-

engineered, generator-loaded expanders maximize the retrieval of useful energy in the

process. Ardali, E.K et al (2009).

This document distinguishes between the recovery of energy from high enthalpy gas and the

Liquid power recovery turbines info sheet, which addresses energy recovery from liquids.

Figure 2.5 Turboexpander

35
There exist two main categories of turboexpander systems: turboexpander-generators and

turboexpander-compressors, as outlined in the American Petroleum Institute (API) 617.

Various terms, such as expander-recompressors, companders, or turboexpanders, describe the

turboexpander-recompressor category. Turboexpander-generators further classify based on

gearbox options: direct drive, external gearbox, or integrally geared. The integral gearing

option facilitates multi-staging, enabling multiple expander stages on a single gearbox.

Typically, the turboexpander-generator unit is fully skid-mounted for simplified

transportation and reduced installation costs.

Different configurations of turboexpander-generators include:

 Direct drive: Eliminates the need for speed reduction, gearboxes, and associated

equipment when feasible.

 External gearbox: Features expanders with patented bearings and a common oil

supply system, ranging from 50 kW to 15 MW.

 Integral gearbox: Mounts the expander wheel directly on the high-speed pinion,

available in standard designs up to 15 MW.

 Multi-stage: Suitable for high pressure ratios and/or high flow rates, accommodating

up to four expanders on a common integral gearbox.

The underlying principle of the expander involves converting energy from high-pressure gas

into mechanical work or shaft power. This energy can be harnessed to drive a generator for

electricity generation, a compressor, or a pump, depending on the application. The

turboexpander replaces conventional control valves or regulators, utilizing the energy in the

motive stream for power generation. Rahman, M (2009).

36
2.7 MODELLING SOFTWARE

In the pursuit of determining critical parameters such as fuel and air mass flow rates,

compressor discharge temperature and pressure, and turbine inlet pressure and temperature

under various operational conditions, researchers have traditionally engaged in intricate

iterations and thermodynamic model equations. However, to streamline these laborious

processes, modeling software has become instrumental, positioning modeling and simulation

as pivotal steps in the preliminary stages of idea approval. A noteworthy contribution in this

domain is Najja's work from 2020, emphasizing the importance of detailed modeling to

assess the combined cycle's performance concerning part load variations and ambient

temperature changes.

Several modeling software options are available for such analyses, including APROS,

Autodynamics, EBSILON Professional, HYSYS, gProms, SIMODIS, PowerSim, MMS,

ProTRAX Aspen, Autodynamics, and TRNSYS. For the specific project at hand, EBSILON

Professional has been chosen for its proficiency in steady-state and semi-dynamic

simulations, as well as its suitability for plant parameter advancements. Dahash (2019) attests

to the applicability of EBSILON Professional's programming conditions for steady-state

estimation.

EBSILON Professional stands out as one of the most widely utilized mass balance and

energy computation programs in European countries, displaying compatibility with Microsoft

environments, high computational speed, and comprehensive features necessary for analysis.

Noteworthy research projects, such as Miguez's solar retrofit study, Jaszczur and Dudek's

investigation of a combined cycle gas turbine and high-temperature nuclear system,

Wallentinen's concentrated solar power gas turbine study, and Wojcik and Wang's steam

power plant optimization, all attest to the software's effectiveness for power plant modeling

and simulation.

37
The study's choice of EBSILON Professional finds validation in its successful application by

Egware (2021) in modeling the SGT5-2000E Gas Turbine in Azura, Benin City, showcasing

consistent results with actual operating data. Similarly, Romuald et al. (2023) employed

EBSILON to model and calibrate the Albioma Bois Rouge thermal power plant in La

Reunion, affirming the software's utility in evaluating plant performances during a transition

from coal to biomass.

Considering its extensive history of successful applications and continuous reliability,

EBSILON Professional emerges as the preferred modeling software for this study. Its

demonstrated accuracy and precision, as highlighted by Matjanov's work in 2020, further

underscore its suitability for designing, modifying, or retrofitting power plants.

2.8 SUMMARY OF LITERATURE

In summary, the literature review highlights the following essentials:

 Combined cycle power plants offer improved power generation output compared to

conventional Brayton and Rankine cycle plants commonly used in Nigeria.

 Ambient conditions, including temperature, pressure, and humidity, significantly impact

the thermal efficiency, power output, and heat rate of combined cycle power plants.

 A higher compression ratio enhances the overall efficiency of Combined Cycle Gas

Turbine (CCGT) systems.

 Exergy destruction in the combustion chamber and Heat Recovery Steam Generator

(HRSG) is influenced by factors like pressure ratio and turbine inlet temperature.

 Natural gas is favored as a cleaner fuel; however, concerns about global warming and

pollution from plant emissions have led to increased consideration of renewable energy

adoption and integration.

The literature review underscores the significant advantages of combined cycle power plants

within the context of gas turbine operations, particularly in comparison to traditional Brayton

38
and Rankine cycle configurations prevalent in Nigeria. Combined cycle plants demonstrate

superior power generation capabilities, attributed to their efficient utilization of exhaust heat

through supplementary steam turbines. Ambient conditions like temperature, pressure, and

humidity notably influence their thermal efficiency and overall performance metrics.

Moreover, higher compression ratios contribute to enhanced efficiency within Combined

Cycle Gas Turbine (CCGT) systems. Furthermore, the study highlights the critical role of

natural gas as a cleaner fuel option; however, increasing concerns over global warming and

pollution necessitate a growing shift towards renewable energy integration alongside gas

turbine operations. This synthesis underscores the comprehensive advantages of adopting

combined cycle technologies, showcasing their pivotal role in advancing sustainable and

efficient power generation practices within the gas turbine sector.

39
 CHAPTER THREE

METHODOLOGY

The purpose of this research is to improve the efficiency of the SGT5-2000E by integrating

into a combined cycle gas turbine and to see how changes in surrounding conditions,

including temperature, relative humidity, mass flow, and part load variations affect the

performance efficiency of a Gas turbine, also seeing the effect of Turboexpanders.

The gas turbine model description based on the simple cycle performance guarantee,

thermodynamic equations, modeling and simulation of the SGT5-2000E model, model validation,

and simulation analysis form the basis of this project's methodology.

3.1 DATA COLLECTION AND OVERVIEW OF AZURA EDO INDEPENDENT

POWER PLANT

Data collected from Azura Edo IPP was through manufacturer’s manual, log books, data sent by

mail from Azura Edo IPP and direct observing from the monitoring screen of the human machine

interface (HMI).

The gas turbine cycle modelled in this project is located at Iwogban-Omoregie Ute Rd, Benin City,

Edo State. The Azura Edo IPP was designed by Siemens energy. The design is based on the model

SGT5-2000E, having three units. It has an installed capacity of 461MW but operating currently at

452MW. It is known for its high efficiency, with its operational flexibility, meaning it can adapt to

varying load demands and grid requirements efficiently. Siemens has focused on reducing

emissions in its gas turbine, and the SGT5-2000E is designed with low emissions in mind. This

helps meet environmental regulations and reduce the environmental impact of power generation.

They have incorporated advanced control systems and digital technologies to optimize the

performance and monitoring of their gas turbine.

The plant was commissioned in 2018, the first of a three-phase construction project of a combined

cycle gas plant with a planned capacity of 1,500MW.

40
3.2 THERMODYNAMIC OPERATIONAL PRINCIPLE OF COMBINED POWER

PLANT

The SGT5-2000E gas turbine power plant operates on the fundamental principles of the Joule

Brayton cycle, which involves a series of thermodynamic processes to convert fuel energy

into mechanical work and ultimately electrical power. The plant's operation can be visualized

through schematic diagrams (Figure 1) and temperature-specific entropy (T-S) diagrams,

providing a detailed understanding of its thermodynamic behavior.

The process begins with ambient air intake at point 1, where the air is drawn into the

compressor. Within the compressor, the air is pressurized and its volume reduced, resulting in

an increase in temperature and pressure. The compressed air then moves into the combustion

chamber at point 2, where it is mixed with fuel and ignited to initiate combustion. This

combustion process generates high-temperature, high-pressure exhaust gases, which exit the

combustion chamber at point 3. The hot exhaust gases then enter the turbine, where they

expand and perform work by driving the turbine blades. As the gases expand through the

turbine, their temperature and pressure decrease, and the energy extracted from the gases

drives the rotation of the turbine shaft. This rotational motion is used to drive the generator,

converting mechanical energy into electrical energy.

A notable aspect of gas turbine operation is the energy requirement of the compressor. The

compressor, responsible for pressurizing the air before combustion, consumes a significant

portion of the mechanical energy produced by the turbine. In fact, approximately 60% of the

total mechanical energy generated by the turbine is used to drive the compressor. This

energy-intensive process reduces the overall efficiency of the gas turbine operating in a

simple cycle, typically resulting in efficiencies below 40%.

41
Despite these challenges, gas turbines remain a popular choice for power generation due to

their relatively compact size, quick start-up capabilities, and ability to operate on various

fuels. Efforts to improve efficiency often involve the integration of combined cycle

configurations, where the exhaust heat from the gas turbine is utilized to produce steam and

drive a steam turbine, further enhancing overall plant efficiency. This comprehensive

approach underscores the continuous evolution and optimization of gas turbine technology to

meet the demands of modern power generation while striving for increased efficiency and

reduced environmental impact.

Following expansion in the turbine, the exhaust flue gas exits at point 4 and enters the Heat

Recovery Steam Generator (HRSG), a crucial component designed to maximize energy

efficiency by capturing waste heat from the flue gas. The HRSG is comprised of several

sections including high-pressure and low-pressure evaporators, a low-pressure economizer,

multiple high-pressure economizers, a low-pressure superheater, and several high-pressure

superheaters.

Within the HRSG, the flue gas transfers its heat to water, producing steam. This steam is then

directed to power the high-pressure steam turbine at point 5 and subsequently the low-

pressure steam turbine at point 7. As these turbines rotate, they drive the generator to produce

electricity.

Following energy extraction in the turbines, the steam exits at point 8 and enters the

condenser, where it undergoes a phase change from steam to water (condensation) at point 9.

The condensed water is then pumped back into the HRSG, completing the cycle by re-

entering the heat recovery process.

This cyclical operation demonstrates the efficiency of combined cycle power plants, where

waste heat from the gas turbine exhaust is effectively utilized to generate additional power

through steam turbines. The integrated system optimizes energy conversion and resource

42
utilization, contributing to improved overall efficiency and reduced environmental impact

compared to simple cycle power plants. The continuous recycling of water in the closed-loop

system further enhances the sustainability of the power generation process, showcasing the

sophistication and effectiveness of modern combined cycle technology in meeting energy

demands with enhanced efficiency and environmental responsibility.

Fig 3.1 Gas Turbine Schematics

Fig 3.2 Simple Brayton cycle and Rankine cycle Ts diagram

43
3.3 MODELLING EQUATIONS

3.3.1 Combustion Chamber

In the furnace of the power plant, a stoichiometric combustion calculation is performed to

ensure efficient and complete combustion of the fuel. This calculation involves determining

the precise amount of air required to completely burn the fuel, achieving a balanced chemical

reaction with no excess oxygen or unburned fuel residues.

Additionally, for conducting an accurate energy balance in the system, it is essential to know

the lower heating value (LHV) of the fuel and its composition. The lower heating value

represents the amount of heat released when a unit mass or volume of the fuel undergoes

complete combustion at constant pressure and the products of combustion are cooled to the

initial temperature of the reactants. The composition of the fuel, including the percentages of

carbon (C), hydrogen (H), sulfur (S), oxygen (O), nitrogen (N), and other elements, is crucial

for calculating the fuel's heating value and understanding its combustion behavior.

Fig 3.3 Fluid Properties of the combustion area

• Mass balance: 𝑀2 – 𝑀4 – 𝑀1 + 𝑀5 = 0

• Energy balance: 𝑄̇ = 𝑀1ℎ1 + 𝑀4ℎ4 + 𝑀4ℎ𝐻𝑊 – 𝑀2ℎ2 – 𝑀5ℎ5 − 𝑄̇𝑟𝑎𝑑

By knowing the LHV and composition of the fuel, engineers can accurately predict the

amount of heat energy released during combustion. This information is vital for optimizing

44
the design and operation of the power plant's furnace, ensuring efficient utilization of the fuel

and maximizing energy conversion into useful work, such as electricity generation.

Additionally, understanding the composition of the fuel aids in assessing environmental

impacts, emissions control, and compliance with regulatory standards related to air quality

and pollution control. Therefore, comprehensive knowledge of fuel properties and behavior is

fundamental for achieving optimal performance and sustainability in power plant operations.

3.3.2 Steam Turbine and Gas Turbine

Fig 3.4 Steam Turbine and Gas Turbine fluid properties

 Energy balance: 𝑀1ℎ1 – 𝑀2ℎ2 = 𝑃𝑡𝑢𝑟𝑏 (1) Eqn 3.1

 Outlet enthalpy h2: ℎ2 = ℎ1 – 𝜂. (ℎ1 – ℎ2𝑠) (2)

Eqn 3.2

 The relationship between inlet and outlet pressure in off-design is described by the

law of ellipses’ of Stodola:

45
 ( )
2
p2
1−

( )
2
m1 p v p1
= 1 . 1N .

( )
2
m1N p1 N v 1 p
1− 2 N
p2 N

Eqn 3.3

46
3.3.3 Compressor and Pump

Compressors and pumps indeed operate based on similar principles of fluid mechanics,

focusing on the movement and pressurization of fluids. Both devices intake fluid at a

relatively low pressure and deliver it at a higher pressure or elevation, but they serve distinct

purposes and handle different types of fluids.

A compressor is designed to increase the pressure of gases, such as air or natural gas. It draws

in low-pressure gas and then compresses it using mechanical energy, reducing its volume and

increasing its pressure. Compressors are widely used in various applications, including

refrigeration systems, air conditioning units, and gas turbines, where pressurized air or gas is

essential for efficient operation.

On the other hand, a pump is used to increase the pressure of liquids, such as water, oil, or

other fluids. Similar to a compressor, a pump draws in liquid at a lower pressure and then

applies mechanical energy to elevate its pressure, enabling it to be transported or utilized in

various industrial, commercial, and residential systems. Pumps are crucial for processes like

water supply, irrigation, wastewater treatment, and hydraulic systems.

Fig 3.5 Fluid Properties of Pump and Compressor

47
 Energy balance: M 2 h2 – M 1 h1=P comp Eqn. 3.4

1
Outlet enthalpy h2 :h2=h1+ .(h2 s – h1) Eqn. 3.5
η

Mass balance: M 1−M 2=0 Eqn. 3.6

Despite the differences in the nature of the fluids they handle, both compressors and pumps

share the fundamental physics of fluid dynamics, specifically the principle of converting

mechanical energy into increased fluid pressure. This process is governed by principles such

as Bernoulli's equation and conservation of mass and energy, ensuring efficient and effective

operation across a wide range of applications in engineering and technology.

3.3.4 Heat Exchanger

Fig 3.6 Fluid properties of a heat exchanger

Enthalpy: 𝑀2ℎ2 – 𝑀1ℎ1 = 𝑄

Eqn 3.7

Enthalpy: 𝑀3ℎ3 – 𝑀4ℎ4 = 𝑄

Eqn 3.8

The heat rate of the gas turbine was computed using Equation (9)

HR = 3600/ 𝜂𝑛𝑒𝑡

48
49
Eqn 3.9

Where 𝜂𝑛𝑒𝑡 is cycle efficiency for gas turbine in simple cycle.

3.4 DESIGN / OFF-DESIGN MODE

In EBSILON® Professional, a simulation software used for designing and optimizing energy

conversion systems, there are two primary calculation modes that serve different purposes

and provide distinct analytical capabilities as shown in Fig 3.7

Fig 3.7 Design/ Off-design mode

Design Mode; In EBSILON® Professional, Design Mode, also referred to as full load mode,

serves as a critical tool for optimizing and specifying energy conversion processes at their

intended design point. This mode focuses on balancing and fine-tuning power plants and their

components under ideal operating conditions—the load for which the system is optimized.

Design Mode involves configuring all components based on manufacturer specifications and

design requirements, ensuring that turbines, compressors, heat exchangers, and other

50
elements operate efficiently and effectively at the designated capacity. The calculations

performed in Design Mode generate reference values that are essential for off-design

simulations, where the behavior of the power plant is analyzed under varying operating

conditions or part-load scenarios. This mode is instrumental in the construction and

evaluation of new energy cycles, enabling engineers to refine designs, optimize performance,

and validate system configurations before implementation. By leveraging Design Mode in

EBSILON® Professional, engineers can make informed decisions to enhance energy

efficiency, reliability, and overall system performance across different operational scenarios.

Off Design Mode; Off-Design Mode, also known as partial load mode, is a pivotal feature

within EBSILON® Professional that facilitates detailed analysis of a power plant's

performance under conditions differing from its design parameters. This mode enables

engineers to simulate and evaluate how the power plant operates at varying loads, ambient

temperatures, pressures, and other operational scenarios distinct from its ideal design

conditions. By exploring these deviations, users can gather critical information about the

plant's behavior and performance, including the impact of cooling water temperatures on heat

rate, variations in ambient conditions on power output, and overall system flexibility. The

insights gained from Off-Design Mode allow engineers to identify optimization

opportunities, refine control strategies, and enhance the plant's efficiency and resilience

across a spectrum of operating conditions. This mode serves as a valuable tool for informed

decision-making, supporting the design, operation, and optimization of energy conversion

systems to achieve optimal performance and reliability in real-world applications.

3.5 MODELING AND SIMULATION WITH EBSILON PROFESSIONAL

EBSILON Professional is modeling software, referenced in section 2.5 of "Energy Balance

and Simulation of the Load Response Power Generating or Process Controlling Network

Structures," often abbreviated as "EBSILON." This tool is valuable for conducting stationary

51
simulations of various thermodynamic power cycles and processes. EBSILON also functions

as a program for calculating mass and energy balances in thermodynamic cycles, allowing

simulation of combined cycle power plant performance under design and part-load conditions

(Dr. Hans-Peter, 2012). The software framework relies on standard components to model

typical power plant elements and incorporates programmable parts with customizable

behaviors to simulate complex power plant operations effectively.

EBSILON utilizes data sourced from the International Association for the Properties of Water

and Steam (IFC67 steam table) along with polynomial models for flue gas and air properties.

It operates as a versatile program system employing a closed solution based on sequential

methods to balance all power plant circuits (Andrea, 2010). The software constructs cycles

using various object types such as components, text fields, pipes, macros (e.g., gas turbines

from the library), value crosses, and graphical elements to comprehensively analyze and

optimize thermodynamic processes.

52
 Fig 3.8 Basic control elements and tool bars of EBSILON software (Andrea, 2010)

53
3.6 OPERATING PARAMETERS OF SGT5-2000E

TURBINE -Number of Stages: 4

FUEL - Natural Gas

GAS TURBINE OPEN CYCLE

Power Output per unit: 145Mw

Number of Units: 3

Total Capacity: 435Mw

Model: SGT5-2000E Formerly V94.2

Frequency: 50Hz

COMPRESSOR

Number of stages: 16

Number of variable inlet guide vane rows: 1

Extraction ports in stages: 5/10

Compressor Pressure Ratio Approx: 12.

COMBUSTION CHAMBERS

Type: Off Board

Number of CC: 2

Number of burners per CC: 8

Number of Ignition Burners per CC: 8

GENERATOR

Type TLR1 115/36

Rating: 166MVA

Power Factor: 0.85

Rated terminal voltage: 15.75+/_5%Kv

Rated current: 6.012KA

54
Speed: 50 cycles/sec

Frequency: 50Hz

TRANSFORMER

Rated power: 173 600 kVA with ODAF cooling

Power definition: According to IEC 76

Power constant on all positions

Rated voltage ratio: 345 000 V ±10% in ±8

steps /15 750 V

Voltage deviation of Generator ± 5% continuously

WINDING VOLTAGE kV/CURRENT A

Position 1 379,5 264,1

HV Position 9 345 290,5

Position 17 310,5 322,8

LV 15,75 6363,7

Vector group: YNd11

Impedance voltage in % at 75° C:

Rated Power 15.75KVA

MVA

Position Short-circuit voltage %1 -173,6 HV / LV 9 1717 –

No-load current: 0,2 %

Maximum permissible short-circuit duration: 2s, IEC

Rated frequency: 50 Hz

55
To simulate the Azura power plant, the initial step involves modeling the gas turbine. The

performance specifications for the simple cycle of the SGT5-2000E, derived from SGT5-

2000E Brochures, are outlined in the table below.

NET ELECTRICAL OUTPUT GUARANTEE Unit

Guaranteed Unit Net MCR Output Simple Cycle 166 MW

NET HEAT RATE GUARANTEE

Guaranteed Unit Net Heat Rate (Simple Cycle) 10,375 KJ/kWh

AMBIENT CONDITIONS

Ambient air temperature 23 oC

Ambient air pressure 0.973 bar

Relative air humidity 0.7 -

OPERATING CONDITION

GT load 100 %

Gas Turbine Exhaust Temperature 541 oC

Exhaust mass flow rate 525 Kg/s

Pressure Ratio 12 -

Lower Heating Value of fuel 50,015 KJ/Kg

Table 3.1 Guaranteed performance for SGT5-2000E

3.6.1 MODELING OF THE GAS TURBINE BASED ON DESIGN CONDITION

The modeling of the power plant was based on several key assumptions:

I) Simulations were conducted under steady-state conditions.

II) Instantaneous effects associated with startup and shutdown were omitted from

consideration during operation.

56
III) Pressure drops across various components were considered at their nominal values.

The SGT5-2000E combined cycle model encompasses several components including the air

compressor, combustion chamber, gas turbine, and generator. EBSILON Professional's

Component Bar and Component Wizard were utilized to integrate these components into the

SGT5-2000E model.

Design performance data from Table 3.1 of the power plant were employed to model the

SGT5-2000E gas turbine. Component 1 (Boundary Input) was used to set ambient air

conditions and fuel temperature. Component 46 (Measured Value Input) was utilized to

specify turbine exit mass flow, temperature, and pressure, and again for setting the relative

humidity of inlet air to the compressor.

In the combustion chamber, the FALAM method for specifying air and fuel flow was

employed. Settings M1, M4, and M5 were selected to calculate the mass flow of air under

design conditions. The gas turbine's pressure ratio was defined, and under the FCHR type of

characteristics, power specifications were established. Component 33 (General Input) was

selected to specify the design power.

57
Fig 3.9 SGT5-2000E gas turbine model

After obtaining the mass of air, the combustion chamber utilized the FALAM method with

the selection of "set M1 and calculate the other flow using ALAMN." In the gas turbine,

under FCHR, "ETAI/ETAIN" was chosen, and the specification of power using component

33 was removed. Component 46 was then used to input the air mass flow, while the exit

temperature and mass flow at the turbine exit were removed before running the simulation

again. Once initial results for the turbine exit were obtained, the model was prepared for the

attachment of the heat recovery steam generator (HRSG).

Transitioning to the combined cycle modeling, all temperatures and mass flows were

specified in the design mode according to Figure 11 by selecting component 46 and setting

them to "on in design mode and off in off-design mode" under FFU. Respective pressures in

the low-pressure turbine and high-pressure turbine were specified within their turbines. The

evaporators were configured to "steam production M2 (externally)" under FSPECD, while

58
FTAPPN was set to "T1 given externally" for heat economizers and superheaters. Given that

the plant incorporates 3 gas turbines and 3 HRSGs, a multiplier component was employed to

reflect this configuration. A multiplier of 3 indicated where fluid or power lines were

combined, while a multiplier of 1/3 indicated where fluids were distributed to the various

HRSGs. The model was then simulated, and nominal values were obtained.

59
Fig 3.10 Combined Cycle Gas Turbine (Design Mode)

60
 3.6.2 OFF DESIGN MODELLING OF THE COMBINED CYCLE GAS TURBINE

Table 3.1 contains data gathered from the Azura power plant under different operating

conditions, specifically focusing on part-load scenarios, which is used for the modeling and

simulation of the SGT5-2000E gas turbine.

GT
P1 P2 T1 T2
S/N Capacity T4 Mf
(mbar) (bar) (C) (C)
(MW)

1 150.40 973.3 10.9 33.4 361.4 521 524.199

2 150.40 973.8 10.9 32.3 360.5 521 523.043

3 150.40 975.4 11.0 31.0 357.8 521 522.406

4 150.40 977.5 11.1 29.9 356.7 521 521.241

5 150.40 980.7 11.0 29.9 356.6 521 520.052

6 150.40 981.7 10.4 29.1 346.7 521 519.007

7 150.40 982.4 10.9 28.5 351.6 521 518.32

8 150.40 982.9 10.9 27.8 349.0 521 517.705

9 150.40 982.1 11.1 27.4 353.3 521 516.71

10 150.40 982.2 10.8 26.2 344.3 521 515.772

11 150.40 983.1 10.5 25.5 341.4 521 504.09

12 150.40 983.2 10.7 25.7 344.1 521 491.231

Table 3.2 Performance Data for SGT5-2000E Off Design

To prepare the model for off-design calculations, a new profile named "partload" was created.

Within this profile, the overall topology of the combined cycle remained unchanged, but

certain adjustments were implemented, such as modifying the power output value using the

controller to simulate different operating conditions.

During the design mode, nominal values are established, serving as the foundation for all

subsequent off-design calculations. Off-design conditions occur when the plant operates

61
under conditions different from the design specifications. These conditions may arise due to

changes in ambient air properties such as temperature, pressure, and humidity, or when the

gas turbine operates at part load, resulting in variations in its power output. These off-design

scenarios are crucial for assessing the performance and behavior of the power plant under

varying operational conditions.

3.6.3 VARIATION OF AIR – FUEL RATIO

In EBSILON, the air ratio parameter known as ALAM plays a critical role in the combustion

chamber by determining the ratio of air mass to fuel mass participating in combustion.

ALAM represents the ratio of the actual air mass entering the combustion chamber to the

stoichiometric air mass required for the complete combustion of the fuel. This parameter

significantly influences the maximum temperature within the combustion chamber.

By increasing the air ratio (ALAM), more air is involved in the combustion process while the

amount of fuel participating decreases. This adjustment leads to a reduction in the maximum

temperature at the combustion chamber's exhaust, subsequently lowering the exhaust

temperature of the gas turbine. Conversely, reducing the air ratio increases the maximum

temperature.

During part-load conditions, where the gas turbine's power output is less than its design

capacity, adjustments to the air-fuel ratio are necessary to maintain a constant turbine exhaust

temperature. This adjustment ensures that the flue gas exiting the gas turbine remains at the

desired operating temperature based on actual data from the power plant. Adapting the air-

fuel ratio in response to part-load demands helps optimize the turbine's performance and

efficiency across varying operating conditions.

To implement variations in the model based on operating conditions, a controller component

(Component 39) was utilized alongside a measured value input (Component 46) to adjust the

exhaust temperature to match actual performance data. Within the combustion chamber, using

62
the FALAM method for specifying air and fuel flow, settings "M1, M4, and M5" were

selected. The controller was then employed to modulate the mass flow rate within a range of

50% to 110% of the base load, performing calculations in off-design mode.

During peak load conditions (at 110% of the base load), constraints on the air mass flow rate

were observed, ensuring it did not exceed the design mass flow rate. Consequently, the

measured value input (Component 46) for exhaust temperature was deactivated. Instead, the

mass flow rate at the compressor inlet was set to the design value, while the mass of fuel was

adjusted using the controller (Component 39) to achieve the desired performance targets. This

dynamic control mechanism allows for efficient operation across varying load conditions,

optimizing the gas turbine's performance while maintaining operational stability.

63
Figure 3.11 Combined Cycle Gas Turbine (75% of base load, off design mode)

64
3.6.4 VARIATION OF PART LOAD

When a gas turbine operates at a power level that is either lower or higher than its nominal

capacity to meet demand requirements, this is referred to as part-load operation. Part-load

operation occurs when the actual load demand deviates from the turbine's nominal load

rating. To manage this variation, a controller is employed to adjust the turbine's output

accordingly.

The off-design model for part-load variation is depicted in Figure 9. This model incorporates

a controller to dynamically adjust the turbine's power output in response to changing load

demands. By implementing this control strategy, the gas turbine can efficiently operate across

a range of power levels, optimizing performance and ensuring effective utilization under

varying operational conditions. The controller serves as a critical component in maintaining

system stability and reliability during part-load operation.

Figure 3.12 Gas turbine operating in 60% part load conditions.

65
In the context of controlling part-load operation in the gas turbine, once the desired load is

inputted into the controller, adjustments are made to the air-fuel ratio accordingly. This

ensures that the appropriate amounts of air and fuel are supplied to generate the desired

power output.

For the analysis spanning from 50% to 100% of the nominal load condition, a specific

controller known as the "GT load level controller" is employed to regulate the exhaust mass

flow rate within the gas turbine combustor. This controller allows for load variation in the

range of 40% to 110%, providing flexibility in adjusting the turbine's performance to match

varying operational demands.

By leveraging these control strategies and load adjustment capabilities, the gas turbine can

effectively operate across a wide range of part-load conditions while maintaining optimal

efficiency and performance. This dynamic control mechanism plays a crucial role in ensuring

the turbine's responsiveness and stability under changing load scenarios.

3.7 VARIATION OF EFFICIENCY IN COMPONENTS

When a gas turbine operates in off-design mode, the efficiencies of its various components

can change significantly due to differences in fluid properties compared to those experienced

during design mode. EBSILON offers a characteristics curve to illustrate how these

efficiencies vary under different operating conditions.

In off-design mode, factors such as altered temperatures, pressures, and flow rates can impact

the performance of components like compressors, turbines, and heat exchangers. The fluid

properties deviate from those assumed during design, leading to changes in efficiency.

EBSILON's characteristics curve is a valuable tool for visualizing and understanding these

efficiency variations. This curve demonstrates how efficiencies, such as compressor

efficiency, turbine efficiency, and heat exchanger effectiveness, respond to shifts in operating

66
conditions. By analyzing these curves, engineers can optimize system performance under

real-world operating scenarios, accounting for off-design conditions to ensure efficient and

reliable operation of the gas turbine plant.

Index M1/M1N ETAI/

Index M1/M1N ETAI/ETAIN
ETAIN
1 0 0.85
1 0 0.5
2 0.4 0.9
2 0.4 0.9
3 0.7 0.95
3 1 1
4 1 1
4 1.2 1.1
5 1.2 1.1
Table 3.3. Variation of efficiency in Table 3.4. Variation of efficiency in

Compressor with mass flow Gas turbine with mass flow

Table 3.3 and 3.4 shows the correction curves for the relationship between the mass flow and

the efficiency

3.8 VALIDATION OF MODEL

To compute the percentage error between the modeled performance and the actual

performance of the SGT5-2000E combined cycle power plant, Equation 3.10 (from

Wallentinen, 2016) is utilized. The equation for calculating the percentage error is typically

given as:

( Actual data−Model data)

%Model Error = ∗100 % Equation 3.10
Actual data

67
 Fig 3.13 Sankey diagram of Azura Edo IPP with combined cycle

3.9 COST ANALYSIS FOR INTEGRATING THE AZURA EDO POWER PLANT

INTO A COMBINED CYCLE PLANT

1. Current Configuration and Cost

SGT5-2000E Gas Turbine: $40 million

Existing Simple Cycle Plant: Typically includes infrastructure, auxiliary systems, and

installation costs, which could be around $20 million.

Total Current Cost: $60 million

2. Cost of Converting to Combined Cycle

To integrate a gas turbine into a combined cycle system, additional components such as a

Heat Recovery Steam Generator (HRSG), a steam turbine, condenser, and associated piping

and controls are required.

Heat Recovery Steam Generator (HRSG): $20 million

68
Steam Turbine: $25 million

Condenser and Cooling Systems: $10 million

Piping, Controls, and Integration Costs: $10 million

Installation and Commissioning: $5 million

Total Cost for Conversion: $70 million

3. Total Cost of the Combined Cycle Plant

Current Simple Cycle Plant: $60 million

Conversion to Combined Cycle: $70 million

Total Combined Cycle Plant Cost: $130 million

Efficiency and Output Gains

1. Simple Cycle Plant Performance

Efficiency: Approximately 35%

Power Output of SGT5-2000E: Around 166 MW

2. Combined Cycle Plant Performance

Efficiency: Approximately 51% (up from 35%)

Total Power Output: 242 MW (166 MW from the gas turbine + additional 76 MW from the

steam turbine)

Financial Analysis

1. Additional Power Output

Increase in Power Output: 76 MW

2. Revenue Gain from Additional Power

Assuming an average electricity price of $0.05 per kWh and an annual operation time of 8000

hours:

Annual Additional Revenue: 76 MW * 8000 hours * $0.05/kWh = $30.4 million

3. Payback Period

69
Additional Investment for Conversion: $70 million

Annual Additional Revenue: $30.4 million

Payback Period: $70 million / $30.4 million per year = 2.3 years

Integrating the Azura Edo Independent Power Plant into a combined cycle plant would

require an additional investment of approximately $70 million, bringing the total plant cost to

around $130 million. This integration would significantly increase the plant's efficiency from

35% to 51% and boost the power output by 76 MW. The annual additional revenue generated

by this increased output would be around $30.4 million, resulting in a payback period of

approximately 2.3 years. Thus, the investment in converting to a combined cycle would be

financially beneficial and enhance the plant's performance and profitability in the long run.

Item Cost (USD)

Current Simple Cycle Plant Costs

SGT5-2000E Gas Turbine $40 million

Infrastructure, Auxiliary Systems, Installation $20 million

Total Current Simple Cycle Plant Cost $60 million

Cost of Conversion to Combined Cycle

Heat Recovery Steam Generator (HRSG) $20 million

Steam Turbine $25 million

Condenser and Cooling Systems $10 million

Piping, Controls, and Integration Costs $10 million

Installation and Commissioning $5 million

Total Cost for Conversion $70 million

Total Cost of Combined Cycle Plant $130 million

Efficiency and Output Gains

Simple Cycle Efficiency 35%

70
Item Cost (USD)

Combined Cycle Efficiency 51%

Simple Cycle Power Output 166 MW

Additional Power Output (Combined Cycle) 76 MW

Total Power Output (Combined Cycle) 242 MW

Financial Analysis

Annual Additional Revenue $30.4 million

Payback Period 2.3 years

Table 3.5 The costs and financial benefits of converting the Azura Edo Independent Power

Plant from a simple cycle to a combined cycle operation.

71
 CHAPTER FOUR

RESULTS AND DISCUSSION

The analysis of results for both design and off-design conditions of the SGT5-2000E gas

turbine is presented in the following section. This analysis encompasses the performance

characteristics and operational behaviors of the gas turbine under various operating scenarios,

including nominal design conditions and deviations from those conditions during off-design

operation.

4.1 MODEL VALIDATION

The validation results of the SGT5-2000E model under both ISO and Azura Edo guarantee

conditions, developed in EBSILON, are presented in Table 5. Equation (3.10) was employed

to calculate the percentage error or deviation between the design data and model data. This

process was undertaken to verify that the model aligns with the ISO design data, which serves

as the foundational profile for all subsequent simulation conditions.

S/ Parameters Units Design Model Differenc Error

N e (%)

1 Power MW 166.0 166.0 0 0

2 Heat Rate KJ/kWh 10375.0 10256.4 118.6 0.0114

3 Thermal Efficiency % 34.7 35.1 0.4 0.0115

4 GT Exhaust oC 541.0 541.0 0 0

Temperature

5 Exhaust mass flow Kg/s 525.0 525.023 0 0

rate

Table 4.1 Results of Model validation for ISO Design Data

72
 The validation results presented in Table 4.1 indicate very low percentage errors between the

model data and ISO specifications, with errors ranging from 0% to 0.0115% across various

performance metrics including net power, heat rate, net thermal efficiency, turbine exhaust

temperature, and turbine exhaust mass flow rate. These findings demonstrate a high level of

agreement between the model predictions and the ISO-designated performance targets.

The consistency observed between the model results and ISO standards is reinforced by

comparisons with similar studies conducted by Miguez Da Rocha (2010), Wallentinen

(2016), Matjanov (2021), and Jingzhi (2015) using EBSILON Professional. These studies

corroborate the accuracy and reliability of the modeling approach employed.

Given the validation against ISO standards, the study proceeds to evaluate off-design

conditions, comparing the model's predictions with operating parameters observed in the

installed SGT5-2000E power plant. This comparative analysis will assess how well the model

emulates the actual operational behavior of the power plant under varying conditions.

4.2 AMBIENT TEMPERATURE VARIATION

The ambient temperature was systematically varied from 33.4°C to 25.5°C within the

EBSILON model to assess the performance of the power plant. The simulated results are

summarized in the table below:

GT Cycle
S/N P1 P2 T1 T2 Mf
Capacity T4 Efficiency
(mbar) (bar) (C) (C) (Kg/s)
(MW) (net)

1 160.511 973.3 12.002 33.4 381.124 541 524.829 34.5

2 161.153 973.8 12.002 32.3 378.934 541 524.847 34.6

3 161.988 975.4 12.002 31.0 376.209 541 524.870 34.7

4 162.804 977.5 12.00 29.9 369.975 541 524.892 34.7

5 163.320 980.7 12.00 29.5 369.238 541 524.904 34.8

6 163.705 981.7 12.00 29.1 367.337 541 524.915 34.9

73
7 164.07 982.4 12.00 28.5 365.918 541 524.925 34.9

8 164.356 982.9 12.00 27.8 364.332 541 524.935 35.0

9 164.578 982.1 12.00 27.4 363.672 541 524.942 35.0

10 165.216 982.2 12.00 26.2 361.11 541 524.962 35.0

11 165.576 983.1 12.00 25.7 359.419 541 524.973 35.1

12 165.694 983.2 12.00 25.5 359.822 541 524.977 35.1

Table 4.2. Variation of Parameters in ambient temperature off-design

Using this dataset, a secondary validation was conducted by comparing the compressor outlet

temperature and the flue gas mass flow rate from the model with actual data obtained from

the gas turbine, as detailed in Table 3.2. The discrepancies between the operating data and

model predictions for different Gas Turbine units are visualized in Figures 4.1 and 4.2.

Additionally, a summary of the resulting errors between the model data and operating data for

various parameters and Gas Turbine units is presented in Table 4.3.

74
 Fig 4.1 Model vs Actual performance
390
Compressor outlet temperature (T2)

380

370

360

350

340

330

320
23 25 27 29 31 33 35

Ambient Temperature (T1)

model actual performance

Fig 4.2 Model VS Actual Performance

526
Mass flow rate of Flue gas(Mf)

524
522
520
518
516
514
512
510
23 25 27 29 31 33 35

Ambient Temperature (T1)

model actual performance

75
 S/N T2 (%) Mf (%)

1 -4.66519092 0.095384

2 -4.2479889 0.057357

3 -4.17859139 0.17228

4 -3.7216148 0.172665

5 -3.54402692 0.038458

6 -5.95240842 -0.01541

7 -4.07224118 -0.03859

8 -4.39312321 -0.03863

9 -2.93574866 -0.19469

10 -4.88237003 -0.1935

11 -5.27797305 0

12 -4.56902063 0.193337

AVG -4.37002484 0.020721

Table 4.3. Model validation using operational data.

In Figures 4.1 and 4.2, it was observed that the model values for the compressor outlet

temperature and mass flow rate of the flue gas exhibited a linear increase compared to the

actual operating data. Table 4.3 presents the validation results, indicating the average error

between the model-predicted values and operating values for the compressor outlet

temperature (-4.37) and the flue gas mass flow rate (0.02).

These validation findings align well with similar studies conducted by Miguez Da Rocha

(2011) and Wallentinen (2015) using the same software. The results demonstrate that the

developed model is adequate and consistent, validating its suitability for further studies in the

thermodynamic evaluation of the SGT5-2000E gas turbine model power plant. The validated

model can now be confidently utilized for in-depth analysis and optimization of the gas

turbine's performance characteristics.

76
 4.3 FUEL AND AIRFLOW VARIATION

The HRSG (Heat Recovery Steam Generator) is a critical component that is sensitive to
Figure 4.3. Inlet Temperature vs GT Power and ST
temperature variations. Significant
Power at constant changes
exhaust in the energy supplied to the HRSG can lead to
temperature
250.00
abnormal conditions, such as inadequate steam generation at the operating pressure within the

evaporator
200.00 section of the HRSG if temperatures are not sufficiently high. To maintain stable

operation, the exhaust temperature of the gas turbine is kept constant. This is achieved by
150.00
adjusting the fuel combustion rate, either by burning extra fuel or reducing fuel input as
100.00
needed.As described earlier in section 3.4.2, to model this condition within EBSILON, a

parameter known as the air ratio is utilized. The table below presents the results obtained
50.00

from this simulation.

𝑚̇ air 𝑚̇15gas 𝑚̇35 40𝑚̇ 45 P(GT)

0.00
T1 T4
0 5 10 20 fuel 25
TLPinlet
30 P(ST) Air

𝜆
T1(oC) HPinlet LPinlet (MW) ratio
(oC) (oC) (kg/s) (oC) (MW)
(kg/s) (kg/s)
P(GT) (MW) P(ST) (MW) (kg/s) (kg/s)
13 521 525.14 535.88 10.74 209.15 183.77 236.75 209.94 74.85 3.17
20 521 512.60 522.55 9.95 209.64 179.85 231.63 182.96 73.33 3.33
22 521 509.13 518.87 9.74 209.77 178.81 230.26 175.76 72.92 3.38
24 521 505.70 515.23 9.53 209.89 177.79 228.93 168.78 72.52 3.42
26 521 502.32 511.65 9.33 210.00 176.80 227.64 162.01 72.13 3.47
28 521 498.99 508.12 9.13 210.11 175.85 226.39 155.44 71.76 3.51
30 521 495.70 504.64 8.94 210.21 174.93 225.19 149.05 71.39 3.55
32 521 492.45 501.24 8.79 210.28 174.09 224.10 144.15 71.06 3.59
34 521 489.24 497.91 8.66 210.32 173.35 223.12 140.41 70.76 3.60
36 521 486.03 494.62 8.59 210.36 172.64 222.21 136.77 70.48 3.62
38 521 482.91 491.37 8.46 210.38 171.99 221.36 133.22 70.21 3.64
40 521 479.83 488.17 8.34 210.39 171.39 220.58 129.77 69.97 3.65
Table 4.4. Variation of air fuel ratio with ambient temperature

77
 Figure 4.4. Inlet Temperature vs Air Ratio
3.70

3.60

3.50

3.40

0 5 10 15 20 25 30 35 40 45
T1 (oC)

78
From the analysis presented in Table 4.4, Figure 4.3, and Figure 4.4, several key observations

can be made:

Effect of Ambient Temperature on Power Output: It is evident that as the ambient temperature

increases, the power developed by both the gas turbine and the steam turbine decreases,

especially when the exhaust temperature from the gas turbine is maintained at a constant

level. This suggests that higher ambient temperatures negatively impact the overall power

generation efficiency of the system.

Impact of Ambient Temperature on Air Ratio: With increasing ambient temperature, there is a

noticeable increase in the air ratio required to maintain a constant exhaust gas temperature.

This adjustment in the air ratio reflects the need to compensate for changing ambient

conditions to achieve consistent operational parameters.

Changes in Turbine Mass Flow with Ambient Temperature: Table 4.4 highlights that as

ambient temperature increases, the mass flow rate through the turbine decreases. This

decrease is attributed to reductions in both air flow and fuel flow. Notably, the reduction in

fuel flow is less pronounced compared to the decrease in air flow, resulting in a higher

demand for fuel to sustain combustion at higher ambient temperatures.

These findings underscore the dynamic interplay between ambient conditions, turbine

performance, and combustion requirements within the power plant model. Understanding

79
these relationships is crucial for optimizing operational efficiency and ensuring stable

performance across varying environmental condition.

80
 CHAPTER FIVE

CONCLUSION AND RECOMMENDATION

5.1 CONCLUSION

This research project underscores the significance of computer engineering software for

modeling and simulating complex systems, exemplified by the SGT5-2000E combined cycle

gas turbine using EBSILON PROFESSIONAL. The study involved modeling the design

mode with guaranteed performance data from the power plant and exploring off-design

scenarios incorporating temperature variations of ambient air and fogging (spray water at

compressor inlet).

The fogging simulation encompassed two modes: one with constant fuel consumption and

another with constant turbine exhaust temperature. Validation of the model results was

performed using actual operating data through error percentage analysis, yielding validation

results ranging from -0.0038% to 0% under design conditions and -0.9202% to 10.24% under

off-design conditions.

Key conclusions drawn from the research include; as ambient temperature increases, the mass

flow rate of air decreases, consequently reducing the power output of the gas turbine. This

temperature effect also diminishes the energy available in the flue gas, thereby reducing

power output in the steam turbine and overall cycle efficiency.

To maintain the design exhaust temperature, additional fuel must be burned to sustain the

combustion process effectively.

Additionally, findings from the simulation indicates that increasing the mass flow rate results

in increased power generation in the steam turbine. However, the HRSG's sensitivity to heat

imposes limitations on the amount of solar steam that can be added (capped at 3 kg/s).

Exceeding this threshold risks issues within critical HRSG components, particularly the

81
evaporator, where insufficient energy could lead to steam generation failure, compromising

the entire steam cycle.

These insights highlight the intricate dynamics and operational constraints inherent in gas

turbine combined cycle systems, emphasizing the value of modeling and simulation tools for

optimizing performance and guiding operational decisions in power plant design and

management.

4.2 RECOMMENDATIONS.

1. Explore strategies to optimize performance under off-design conditions, such as

developing control algorithms to dynamically adjust operating parameters in response to

changing ambient conditions. This could improve operational flexibility and efficiency,

especially during transient operating conditions.

2. Investigate alternative cooling methods or technologies to mitigate the impact of high

ambient temperatures on gas turbine performance. This could include exploring advanced

fogging techniques, inlet air chilling systems, or hybrid cooling solutions to maintain

optimal turbine performance across a wide range of ambient conditions.

3. Focus on HRSG design and operation to maximize efficiency and reliability. This could

involve optimizing heat transfer surfaces, improving water chemistry management, and

implementing advanced control strategies to enhance HRSG performance and prevent

operational issues, particularly in critical components like the evaporator.

4. Sustainability and Environmental Impact: Consider the environmental impact of power

generation operations and explore strategies to enhance sustainability. This could involve

evaluating emissions reduction technologies, implementing energy-efficient practices, and

assessing the feasibility of incorporating carbon capture and storage (CCS) technologies

to reduce greenhouse gas emissions.

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5. Establish a comprehensive long-term performance monitoring and maintenance program

to track the performance of the gas turbine combined cycle system over time. Regular

monitoring and analysis of operational data can help identify trends, diagnose potential

issues, and optimize system performance through proactive maintenance and

troubleshooting.

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