CHAPTER III

TECHNICAL DESIGN AND REQUIREMENTS

Overview

Combined Cycle Power Plant is a type of power plant that combines two or more

thermodynamic cycles. The main advantage of this type of power plant is that by

combining two or more thermodynamic cycles, the overall efficiency and output

electrical power of the plant is higher compared to a traditional single cycle power plant

and it also has a lower emission. Combined cycle power plant is widely used worldwide

because of its advantages.

The output thermal efficiency of a single cycle power plant typically ranges from

35-40% and the remaining heat that are left after the combustion process are totally

wasted. By combining two cycles, such as Brayton and Rankine cycles, we can produce a

higher thermal efficiency of about 50-60 % which is high and desirable in the field of

power production industry.

The combined cycle power plant is a merger of heat engines that works together

and they also have the same source of heat. It is composed of a gas turbine that utilizes

the heat produced by the combustion of natural gas, and a Heat Recovery Steam

Generator (HRSG) that uses the heat of the exhaust gases from the gas turbine to

evaporate the water and create steam that turns the steam turbine thus producing an

additional power output. The output of the steam turbine is approximately 50 % of the

gas turbine output.

The main source of heat of a combined cycle power plant is natural gas which is

cheaper compared to other fossil fuels. The emissions of natural gas is also cleaner
compared to other fuels like coal. Natural gas emits 60% less C O 2 compared to coal.

Also because of utilizing the exhaust heat from the gas turbine as the main source of

energy for the HRSG, the overall cost of fuel consumption is reduced.

Working Principle

Figure 10. A simple combined cycle, including open Brayton Cycle and Rankine Cycle.
Source: Appl. Sci. 2019, 9, 4190

A combined cycle power plant (CCPP) is a type of power plant that uses natural

gas as the main fuel. Its main components are gas turbine, combustion chamber,

generator, heat recovery steam generator, steam turbine, condenser and pump. The

overall efficiency ranges from 50% to 60% of a simple design. As stated in its name, a

combined cycle comprises of two major cycle which are: Brayton cycle and Rankine

cycle.

Brayton cycle involves the compressing of air into one or more stages depending

on the design of the plant to increase their pressure by reducing its volume. Then, the
compressed gas will undergo combustion in the combustion chamber where the air and

fuel are mixed to form products like water in a form gas (steam), carbon dioxide, and

nitrogen. The gases are formed in the gas turbine making them spin. The spinning of

motor convert mechanical into electrical energy to form electricity.

In the Rankine Cycle, the heat of the exhaust gases from the Brayton Cycle will

be captured by the Heat Recovery Steam Generator (HRSG) and utilized it to form steam

from the feed water. This steam will be delivered into the steam turbine, the heat energy

of the steam will create mechanical energy into the turbine blades and this energy will be

transform into electrical energy using a generator for additional electricity. Some of the

steam can also be recycled by using it in initially heating the feed water while the

remaining steam will be condensed in the condenser and the condensate will also be

pumped back to the HRSG as feed water.

Figure 10. Plant Layout

 Figure 10 illustrates our plant layout. The proposed 400 MW Combined Cycle

Power Plant that will be situated in Brgy. Talisay, Calaca, Batangas will occupy a land

area of approximately 170,000 square meters or 17 hectares.

Main Components

a) Gas turbine

Gas turbine is equipment that converts the kinetic energy from the gas into

mechanical energy, it is made up of several rotating blades that converts the

energy produced by the combustion of the air-fuel mixture. Gas turbine blades

usually divided into two parts the compressor blades, stator blades and the

Turbine. Stator blades reduces the flow area of the air resulting in increase in

energy, it acts as a nozzle. Turbine blades harvest the energy produced by the

combustion of the air-fuel mixture into mechanical energy. The turbine blades are

design in such way to produced pressure difference resulting to air lift and causes

the blades to rotate.

Figure 11. Open-cycle gas turbine

Source: Encyclopedia Britannica, Inc.

b) Combustion chamber

Combustion chamber converts the chemical energy of the air-fuel mixture

into kinetic energy that makes the turbine blades spin, it is located between the

compressor blade and turbine blades is the primary source of heat, it most perform
 continuously to provide the energy required of the turbine. The compressed air is

being mix with the fuel and heat will be added to ignite. After combustion the air-

fuel goes through the turbine. The amount of the fuel and air must be sufficient to

perform a complete combustion

Figure 12. Gas Turbine

Source: mpoweru.com

c) Generator

Generator is the component that converts the mechanical energy into

electrical energy, it is connected to the turbine by means of shaft.

Figure 13. Steam Turbine Generator

Source: www.power-spares.com

d) Heat Recovery Steam Generator

The heat recovery steam generator (HRSG) is a component that is

connected to the exhaust of the gas turbine. During the operation of the plant, the
 gas turbine exhausts a large volume of exhaust gases. HRSG utilizes the thermal

energy of this exhaust gases for the purpose of steam generation which is the

working fluid for the steam turbine.

Figure 14. Heat Recovery Steam Generator

Source: eng.viro-engineering.com

e) Steam Turbine

Steam turbine is a component that utilizes the thermal energy of the

generated steam in order to rotate the rotor blades of the turbine. The rotation of

the blades will apply mechanical work on the shaft connected to a generator thus

producing additional power output. The steam will then go to the condenser after

using it to operate the steam turbine.

Figure 15. Steam Turbine

 Source: www.plantautomation-technology.com

f) Condenser

Steam condenser is a component that is used to condensate the exhaust

steam from the steam turbine into water. The condenser eliminates the latent heat

of the steam and the heat will go with the cooling water.

Figure 16. Steam Condenser

Source: www.indiamart.com
g) Pump

Pump is the component that introduces feedwater into the Heat recovery

steam generator. The feedwater may come from freshwater sources such as lakes,

rivers and sea, or it might be the condensate water from the condenser.
 Figure 17. GP Ring-Section Type Pump
Source: www.ruhrpumpen.com

Design Options

Design Option 1

Figure 18. Design Option 1

Figure 18 illustrates the complete diagram for our Design Option 1. Our first

design option is a Gas Turbine Intercooling combined with a Simple Steam Cycle. In this

design option, we chose to incorporate an intercooler in the air compressor of the gas
turbine and a typical configuration of a steam turbine. The gas turbine assembly is

composed of a Low-Pressure Compressor (LPC), High-Pressure Compressor (HPC),

intercooler, combustion chamber, gas turbine and a generator while the steam turbine

assembly is composed of the Heat Recovery Steam Generator (HRSG), steam turbine,

generator, condenser, and a feed pump.

Incorporating an intercooler in the air compressors will have a significant

advantage in the overall efficiency of the power plant. Intercoolers are used to reduce the

temperature of the gas after each stage of compression. In a combined cycle power plant,

high compression ratios are used which creates a huge increase in temperature after each

compression. It is necessary to reduce the temperature of the compressed gas to the

allowable limit that the compressor equipment could handle to avoid malfunction and

damage. Intercooling also lessens the threat of corrosion of the compressor material, it is

because intercooling allows the moisture in the air to condense into liquid thus reducing

the work necessary for compressing the gas. Intercooling will increase the compressor

efficiency thus saving power and increasing the total output of the power plant.

Figure 19. TS Diagram of Design Option 1

 Figure 19 illustrates the TS diagram of the whole cycle for design option 1.

Design option 1 shows the combined processes of the Gas Intercooling Cycle at state

points 1 to 7 and Simple Rankine Cycle at state points at state points 7 to 11. The process

started at state points 1 to 2 where an isentropic compression of air within the low-

pressure compressor occurs. Meanwhile, at state points 2 to 3, the process was an isobaric

heat rejection within the intercooler. At state points 3-4, there will be an isentropic

compression of air at the high-pressure compressor. At state points 4-5, the process is an

isobaric heat addition done by combusting the air and fuel mixture in the combustor. At

state points 5-6, there will be an isentropic expansion at the turbine blades and lastly at

state points 6-7 there will an isobaric heat rejection at the HRSG. The Rankine Cycles

starts at state points 7 to 8, where the exhaust heat from the gas turbine causes an isobaric

heat addition at the HRSG. At state points 8 to 9, there will an isentropic expansion of

steam at the turbine blades. At state points 9 to 10, there will an isobaric heat rejection

when the steam goes through the condenser and lastly at state points 10 to 11, the

feedwater will be adiabatically pumped into the HRSG.

The overall process of this design option starts with compressing the air in two

stages, the then the compressed gas will be mixed to the fuel in the combustion chamber.

The combusted air will expand into the gas turbine and the exhaust gas will be utilized as

the source of heat for the steam turbine cycle. The exhaust gas that will be released by the

gas turbine goes through the Heat Recovery Steam Generator (HRSG). The gas will

increase the temperature of the feedwater inside the HRSG and will convert it into steam.

The steam will flow to the next turbine which is the steam turbine. In the steam

turbine, the steam that contains mechanical energy will rotate the blades, then the
generator will convert the mechanical energy produced by the turbine into electrical

energy. Lastly, the excess steam released by the steam turbine will goes through the

condenser. In the condenser the heat is extracted converting the steam into liquid state,

the liquid condensate will be pump back to the HRSG to be used again as feedwater.

DESIGN OPTION 1

Net Output = 288 MW

Net Heat Rate = 9295 kJ/kWh
Net Efficiency = 38.7 %

Gas Turbine Exhaust Temperature = 621℃

Turbine Speed = 3000 rpm
9F.04 Gas Turbine
This gas turbine contains an
intercooler.

Net Output = ≤ 300 MW

Steam Temperature = 600℃
Steam Pressure = 190 bar
Reheat temperature = ≤ 600℃
Steam Turbine
Condensing Pressure = 0.4 MPa
STF-A650 Steam Turbines
(Reheat) These turbines have a reheater
with separate HP section and LP
sections.

m3
Capacity = up to 900
hr
Head = ≤ 4,000 m

Feed Pump Maximum Pressure = ≤ 416 bar

Temperature = ≤ 205 ℃
GP Ring-Section Type Pump It can be used in high pressure
and high temperature
applications.
 Cooling Medium = Sea Water

Weight = 5000 – 6100 kg

Condenser

Exhausted Steam Condenser Pressure = 0.4 MPa

KhV 200

Steam Temperature = 501-777K

Steam Pressure = 0.7-7.3 MPa

HRSG

Frequency = 50Hz
HRSG-87/88

Output Range = 360 MVA

Power Factor = 0.85
Generator
Efficiency = up to 98%

TOPACK Generator Frequency = 60 Hz

Design Option 2
 Figure 20. Design Option 2

Figure 20 illustrates the complete diagram for our Design Option 2. Our second

Design Option is a Simple Gas Turbine Cycle combined with Reheat Regenerative Steam

Cycle. In this design option, we decided to incorporate a reheater and an Open Feed

Water Heater (OFWH) in the steam turbine assembly. The gas turbine assembly shows a

typical gas turbine which composed of an air compressor, combustion chamber, gas

turbine and generator while the steam turbine assembly shows a modified reheat

regenerative steam cycle composed of an Heat Recovery Steam Generator (HRSG), High

Pressure Steam Turbine (HPT), Low Pressure Steam Turbine (LPT), a reheater found

inside the HRSG, Condenser, Condensate Pump, Open Feed Water Heater (OFWH), and

a Feed Pump.

Incorporating a reheater into the steam turbine makes some improvement to the

output of the power plant. A reheater is a component that acts as a heat exchanger for the

steam. The addition of a reheater will introduce a multi-stage steam turbine. In this design
option it is composed of a High-Pressure Steam Turbine (HPT) and a Low-Pressure

Steam Turbine (LPT). Reheating of steam will increase the thermal efficiency of the

plant, instead of exhausting the steam after going through a single steam turbine, we are

designing to run the steam back to a reheater found in the HRSG to maximize the use of

all the heat from the steam. The steam will be reheated into a superheated state and will

be utilized again to run the second steam turbine. During reheating, the moisture content

of the steam is reduced to avoid corrosion into the steam turbines. The high moisture

content of the steam will cause damage into the turbine blades, so reheating helps a lot in

avoiding this phenomenon. The addition of the Open Feed Water Heater (OFWH) into

the steam cycle for regeneration helps a lot in improving the efficiency of the power

plant. The regeneration cycle is all about utilizing the remaining heat of the exhaust

steam from the steam turbines. The heat from the steam will be used to partially increase

the temperature of the feedwater before pumping it into the HRSG. Utilizing the heat of

the exhaust steam will increase the thermal efficiency and will reduce the work necessary

to heat the feedwater into steam.

Figure 21. TS Diagram of Design Option 2

 Figure 21 illustrates the TS diagram of the whole cycle for design option 2.

Design option 2 shows the combined processes of the Brayton Cycle at state points 1 to 5

and Reheat Regenerative Rankine Cycle at state points at state points 6 to 14. The process

started at state points 1 to 2 where an isentropic compression of air within the compressor

blades occur. Meanwhile, at state points 2 to 3, the process will be an isobaric heat

addition at the combustion chamber by combusting the mixture of fuel and compressed

air. At points 3 to 4, there will be an isentropic expansion of gas at the turbine blades and

lastly at points 4-5, there will isobaric heat rejection at the HRSG. At state points 5 to 6,

there will be an isobaric heat addition in the feed water to turn it into steam. Next, at state

points 6 to 7, there will be an isentropic expansion of steam into the HPT blades. Next, at

state points 7 to 8, the steam will undergo re-superheating into the HRSG then at state

points 8 to 9, the re-superheated steam will expand to the LPT blades. At points 9 to 13,

part of the steam from the LPT will be utilize to regenerate heat for partially heating the

feedwater. On the other hand, at state points 10 to 11, the remaining steam will be

condensed into the condenser and there will an isobaric rejection of heat. At state points,

11 to 12, the condensed steam will then be pumped into the OFWH, then at state points

12 to 13, these steam will be mixed with the partially heated feedwater into the OFWH

and lastly, at state points 13 to 14, the feedwater will then be pumped back into the

HRSG to undergo the cycle again.

The overall process of this design options starts with compressing the air in the air

compressor; the compressed air will be fed into the combustion chamber and will be

mixed with the fuel. The product of the combustion will then expand into the gas turbine

and will govern the rotation of the blades to create mechanical energy that will be
converted into electrical energy using a generator. The exhaust gas from the gas turbine

will not be disposed directly into the atmosphere, it will first pass through the HRSG to

utilize it as the heat source of the steam cycle. The heat will be used to increase the

temperature of the feed water to create steam that will be feed into the steam turbines.

The steam will first go to the HPT and instead of condensing it afterwards, the steam will

be run again into the HRSG to reheat it into a superheated state that will go to the LPT.

The two turbines are coupled into a single shaft and they are working together in

producing mechanical energy that will be converted by the generator into electrical

energy. Some of the exhaust steams from the LPT will go to the OFWH and will be used

to initially heat the feed water, while the remaining steam will be condensed into the

condenser. The condensate will be pump by a condensate pump back into the HRSG as

the feed water.

DESIGN OPTION 2

Net Output = 310 MW

kJ
Net Heat Rate = 9000
kWh
Net Efficiency = 40 %
Exhaust Temperature = 918 K
Gas Turbine
Exhaust Gas Flow = 650 kg/s
The SGT6-8000H was the very
SGT6-8000H first air-cooled H-class gas turbine
on the 60 Hz market and has since
demonstrated its high operational
flexibility and low lifecycle costs.

Steam Turbine Net Output = ≤ 100 MW

Inlet Temperature = 565℃
Inlet Pressure = 16.5 kPa
 Reheat Temperature == ≤ 565℃
Reheat Pressure = 4.5 MPa
Condensing Pressure = 0.03 MPa
The SST-800 is designed for a
direct coupled generator or
mechanical drive. Power output
with dual casing solution is up to
250 MW.

m3
Capacity = up to 63,137
hr
Head ≤ 100 m
Maximum Pressure ≤ 20 bar
Condensate
Pump Temperature = -30 to 135 ℃
Its applications include
VCT Vertical Circulating Pumps conventional steam, combined
cycle, Integrated Gasification
Cycle and more.

Steam Temperature = 499 K

Steam Pressure = 0.6 – 7.85 MPa

Frequency = 50 Hz
HRSG HRSG 17-96

Cooling Medium = sea water

Condenser
Weight = 173 / 179.5 kg
kg
Condensate Cooler Mass Flow Rate = 6.3889
s

Net Output = 360 MVA

Generator Power Factor = 0.85

Efficiency = up to 98%
 Frequency = 60 Hz

Design Option 3

Figure 22. Design Option 3

 Figure 22 illustrates the complete diagram for our design option 3. Our third

design option is a Gas Turbine Intercooling combined with Reheat Regenerative Steam

Cycle. This design option is more like a combination of our first and second design

options because we combined the intercooling process in the gas turbine and reheat

regenerative process in the steam turbine. The gas turbine assembly is composed of

several components like the Low-Pressure Compressor (LPC), High Pressure Compressor

(HPC), intercooler, combustion chamber, gas turbine and a generator. The steam turbine

assembly is composed of a Heat Recovery Steam Generator (HRSG), High Pressure

Steam Turbine (HPT), Low Pressure Steam Turbine (LPT), a reheater found inside the

HRSG, Condenser, Condensate Pump, Open Feed Water Heater (OFWH), generator and

a Feed Pump.

In this design option we are trying to create a much-complicated design

composed of assemblies that are already proven in increasing the efficiencies of a power

plant. We apply the concept of intercooling into the gas turbine to reduce the necessary

work to compress the input gas, also intercooling helps avoid the problem of corrosion in

the turbine blades by reducing the moisture content of the compressed gas. Intercooling

promotes isothermal compression that will help prevent damage into the compressor

materials. This process of intercooling the gases is proven to lessen the cost of

compression work and increase the compression efficiency of the power plant.

Incorporating a reheater into the steam turbine will increase the thermal efficiency

of the power plant by utilizing the remaining heat of the steam to further rotate the blades

of a second turbine. Reheating will also protect the blades of the turbine from corrosion

by reducing the moisture content of the steam. We also used the regeneration process in
the steam turbine by utilizing the heat of the exhaust steam from the turbines to initially

increase the temperature of the feed water, thus increasing the thermal efficiency and will

reduce the work needed to turn the feed water into steam.

Figure 23. TS Diagram of Design Option 3

Figure 23 illustrates the TS diagram of the whole cycle for design option

3. Design option 3 shows the combined processes of the Gas Intercooling Cycle at state

points 1 to 7 and Reheat Regenerative Rankine Cycle at state points at state points 7 to

15. The process started at state points 1 to 2 where an isentropic compression of air

within the low-pressure compressor occur. Meanwhile, at state points 2 to 3, the process

will be an isobaric heat rejection at the intercooler, this is done to reduce the necessary

compression work. At points 3 to 4, there will be an isentropic compression of gas in the

high-pressure compressor. At state points 4 to 5, there will be an isobaric addition of heat

by combusting the air-fuel mixture. At state points 5 to 6, the products of combustion will

the expand isentropically into the gas turbine blades and at state points 6 to 7, the exhaust

gases will then go to the HRSG to heat the feedwater and at state points 7 to 8, the
feedwater will become a superheated steam. At state points 8 to 9, the steam will undergo

an isentropic expansion in the HPT blades. Next, at state points 9 to 10, the steam will be

re-superheated inside the HRSG and at state points 10 to 11, the re-superheated steam

will now isentropically expand into the LPT blades. At points 11 to 15, some of the

exhaust steam will be utilized to partially heat the feedwater of the system. At state points

12 to 13, the remaining steam will be condensed into the condenser and will cause an

isobaric rejection of heat. At state points 13 to 14, the condensed steam will now be

pumped back as feedwater for the cycle. At state points 14 to 15, the condensed steam

will be mixed with the partially heated feedwater from the regenerator and at state points

15 to 16, the feedwater will be pumped back into the HRSG and will undergo the whole

process again.

The overall process of this design option starts in the multi-stage air compressor,

the air will be isothermally compressed into two stages before mixing into the fuel inside

the combustion chamber. The combustion of air and fuel will create a large amount of

heat energy that will rotate the blades of the gas turbine thus producing mechanical

energy, this energy will be converted by the generator into our output electrical energy.

The exhaust gases from the gas turbine will be used to heat the feed water inside the

HRSG to create steam. The steam will be used to rotate the blades of our steam turbines,

we are using a reheater between the steam turbines to reduce the moisture content of the

steam and protect the blades of the turbines. Using a reheater will always introduced the

concept of multi-stage turbines. The exhaust steam from the turbines will be divided,

some of the steam will condense in the condenser and the remaining steam will be
utilized to partially heat the feed water. The condensate from the condenser and the steam

mixed with the feed water will be pumped back to the HRSG as feed water.

DESIGN OPTION 3

Net Output = 215 MW

kJ
Net Heat Rate = 8780
kWh
Net Efficiency = 41%
Gas Turbine
Exhaust Temperature = 599℃
Turbine Speed = 3000 rpm
SGT5-4000F
This gas turbine contains an
intercooler.

Net Output = ≤ 700 MW

Steam Temperature = 565℃
Steam Pressure = 185 bar

Steam Turbine Reheat temperature = ≤ 565℃

Condensing Pressure = 0.4 MPa
GE STF-D650 These turbines have a reheater
with separate HP section and LP
sections.

Capacity = 7000 gpm

Temperature = 838 K
Feed Pump Pressure = 140 bar
Head = 1494 K
VLT Vertical Process Pump It can be used in any applications.

Cooling Medium = Sea Water

Condenser Cooling Surface = 4.5 m2

Pressure = 0.35 MPa

Exhausted Steam Condenser
 KhV type
Steam Temperature = 473-788K

Steam Pressure = 8-560.56 MPa

HRSG

Frequency = 50 Hz
HRSG-90

Output Range = 690 MVA

Power Factor = 0.85
Generator Efficiency = up to 99%

Frequency = 60 Hz
TOPGAS Generator

The following formulas will be used in the evaluation of the all the components in

every design option:

1. State points 1 – 2, Compressor

T2
=¿
T1

2. Compressor Efficiency

T 2−T a
ɳ c=
T b ' −T a

3. State points 3 – 4, Turbine

T3
=¿
T4

4. Turbine Efficiency

T 3−T 4 '
ɳ t=
T 3 −T 4

5. Efficiency
 Mechanical Efficiency, ɳm

Brake Power
ɳ m=
Indicated Power

Generator Efficiency, ɳg

Generator Output
ɳ g=
Brake Power

6. Indicated Heat Rate

m f x 3600 x Qh
HR i=
IP

7. Ideal Work for Compressor

W c = ma C pa ( T 2−T 1 )

8. Actual Work for Compressor

W c = m a C pa ( T 2 ' −T 1 )

9. Ideal Work for Compressor

W T = mg C pg ( T 3−T 4 ' )

10. Actual Work for Turbine

W T = m g C pg ( T 3−T 4 )

11. Net work, Wnet

 W p = m g C pg ( T C −T d )−m a C pa ( T b ' −T a )
'

W net = W T ' −W C '

12. Pump Work, Wp

W p = v3 ( change∈ pressure)

13. Actual Pump Work

W Pump ms
W P '=
ɳP

14. Amount of Cooling Water

Mass Balance at the Condenser

ms ( h8 −h9 ) =mw Cpw ( t cwo −hcwi )

15. Steam Turbine Work, Wt

W t =ms ( h1 −h2 )

16. Thermal Efficiency

W net
ɳ th =
QA

17. Overall Efficiency

Overall Efficiency=( nthg +nths )−(nthg∗nths )

Design Option 1
 GAS TURBINE

Specifications

Power Output = 281 MW Pressure Ratio = 24:1

Heat Rate = 9295 kJ/kWh Exhaust Mass Flow = 900 kg/s

Gross Efficiency = 38.7% Exhaust Temperature = 621℃

Gas Intercooling Cycle

T 1 = 27.3 ℃ = 300.3 K

P1= 101.325 kPa

r p = 24

T4 =621℃ = 894 K

Solution:

 Solving for P4

P4
r p=
P1

P4
24=
101.325 kPa

P4 =¿2431.8 kPa

 Solving for P2 and P3

P2=P3 =√ P1 P4
 P2=P3 =√ (101.325 kPa)(2431.8 kPa)

P2=P3 =323.3301599kPa

 Solving for the pressure ratio of every stage

P2
r p=
P1

323.3301599 kPa
r p=
101.325 kPa

r p =3.191020572

 Solving for T2

k−1
T2
=(r ¿¿ p) k ¿
T1

1.4 −1
T2 1.4
= 3.191020572
( )
300.3 K

T 2=418.3456131 K

 Solving for T4

T1 = T3 = 300.3 K
k−1
T4 P
T3 ( )
= 4
P3
k

T4 2431.8 kPa 1.4−1

300.3 K
= (
323.3301599 kPa ) 1.4

T 4=534.4677625 K

 Solving for T5

P4 =P5=2431.8 kPa

T6 = 621℃ = 894 K
 k−1
P5 T5
( )
P6
k
=
T6

1.4−1
1.4 T5
(17.62) =
894 K

T 5=2029.26706 K

STEAM TURBINE

Specifications

Model = GE STF-A650 Inlet Temperature = 600℃

Power Output = 85 to 300 MW Reheat Temperature = ≤600℃

Inlet Pressure = ¿190 bar Condensing Pressure = 0.4 MPa

Reheat Regenerative Rankine Cycle

 at state point 8

h8 =h @190 ,̄ 600℃

kJ
h8 =3546
kg

s8 @190 ,̄ 600℃

kJ
s8=6.5366 = s9
kg . K

 at state point 9

kJ
s9 =s 8=3546
kg . K
 s9 =s f + x s fg @ 4 ¯¿

kJ kJ
6.5366 = 1.77666 + x ¿)
kg . K kg . K

x=0.9298146231

h 9=h f + x h fg @ 4 ¯¿

kJ kJ
h 9=604.74 +(0.9298146231)(2133.8 )
kg kg

kJ
h 9=2588.778443
kg

 at state point 10

h10=hf @ 4 ¯¿

kJ
h10=604.74
kg

v10 =v f @ 0.4 MPa

−3 m3
v10 =1.0836× 10
kg

w p=v 10 ∆ P

−3 m3
w p=(1.0836× 10 )(19000 kPa−400 kPa)
kg

kJ
w p=20.15496
kg

 at state point 11

w p=h 11−h 10
 h11 =w p +h10

kJ kJ
h11 =20.15496 +604.74
kg kg

kJ
h11 =624. 89446
kg

 Solving for the Heat Added

w net
nt =
QA

281 MW
0.387=
QA

Q A =726.0981912 MW

 Solving for the mass of fuel

Q A =mf LHV

kWh 3600 s
726098.1912 kW =m f (13.1 )( )
kg hr

kg
m f =15.78002643
s

 Solving for the mass of air

mt =ma+ mf

m a=mt −m f

kg kg
m a=900 −15.78002643
s s

kg
m a=884.2199736
s
 at state point 4-5

Q A =m t C pg (T 5−T 4 )

kg kJ
726098.1912 kW =(900 )(2.34 )(T 5 −534.4677625 K )
s kg . K

T 5=887.8324559 K

 solving for the mass of steam

Interpolating using the table of specific heat constant at different temperature

TEMPERATURE CP
600 K 1.214
621 K C pg
700 K 1.239

C pg=1.21925

m t C pg ( T 6−T 7 )=m s (h8−h 11 )

kg
(900 )(1.21925) ( 894 K −777 K )=m s ¿)
s

kg
m s =¿43.95151878
s

 Solving for the Turbine Work

W steamturbine=m s ( h8−h 9 )

kg kJ kJ
W steamturbine=(43.95151878
s (
) 3546 −2588.778443
kg kg )
W steamturbine=42071.40731 kW
 Solving for the actual pump work

W pump
W pump ,actual = (m s )
np

kJ
20.15496
kg kg
W pump ,actual = (43.95151878 )
0.84 s

W pump ,actual =1054.572742 kW

 Solving for the net steam work

W net steam =W steamturbine−W pump, actual

W net steam =42071.40731 kW −1054.572742 kW

W net steam =43.1259137 MW

 Solving for the total net work

W net ,total=W net , gas + W net ,steam

W net ,total=281 MW + 43.1259137 MW

W net ,total=324.1259137 MW

 Solving for the thermal efficiency

W net , total
nthermal = ×100 %
QA

324.1259137 MW
nthermal = ×100 %
726.0981912 MW

nthermal =44.6394052 %
  Solving for the produced energy

EP=BP (n generator )

EP=(324.1259137 MW )(0.95)

EP=307.919618 MW

 Solving for the overall efficiency of the plant

EP
n overall= ×100 %
QA

307.919618 MW
n overall= ×100 %
726.0981912 MW

n overall=42.40743494 %

Design Option 2

GAS TURBINE

Specifications

Power Output = 310 MW Pressure Ratio = 21

Heat Rate = <9000 kJ/kWh Exhaust Mass Flow = 650 kg/s

Gross Efficiency = >40% Exhaust Temperature = 918 K

Brayton Cycle

T 1=27.3 ° C=300.3 K

P1=101.325 kPa

r P=21
Solution:

Compressor Inlet Temperature, T 1=27.3 ° C=300.3 K

Compressor Inlet Pressure, P1=101.325 kPa

k−1
T2
=( r p ) k
T1

1.4 −1
T2 1.4
= 21
( )
300.3 K

T 2=716.6915327 K

P2
r P=
P1

P2
21=
101.325 kPa

P2=2127.825 kPa

STEAM TURBINE

Specifications

Power Output = up to 200 MW Reheat Temperature = ≥565°C

Inlet Pressure = 16.5 kPa Reheat Pressure = 4.5 MPa

Inlet Temperature = 565°C Condensing Pressure = 0.03 MPa

Reheat Regenerative Rankine Cycle

Finding Enthalpy, Entropy and Specific Volume at State Points

 h6 = h at 16.5 MPa and 565°C = 3473.95 kJ/kg

h7 = hg at 7.2 MPa = 2769.4 kJ/kg

h8 = h at 7.2 MPa and 565°C = 3564.9 kJ/kg

s8 = s at 7.2 MPa and 565°C = 6.9771 kJ/kgK

h9 = h at 4.5 MPa and s9 equal to s8 = 3399.037908 kJ/kg

h10 = hg at 0.03 MPa =2625.3 kJ/kg

h11 = hf at 0.03 MPa = 289.23 kJ/kg

h13 = hf at 4.5 MPa = 1121.9 kJ/kg

v11 = vf at 0.03 MPa = 0.0010223 m3/kg

v13 = vf at 4.5 MPa = 1.2692 m3/kg

 Solving for Pump Work 1

W P 1=v 11 (P13−P11 )

W P 1=0.0010223 m3 /kg(4500−30) kPa

kJ
W P 1=4.569681
kg

 Solving for Enthalpy at state point 12

h12=W P 1 +h11
 kJ
h12=4.569681 kJ /kg +289.23
kg

kJ
h12=293.799681
kg

 Solving for Pump Work 2

W P 2=v 13(P14 −P13)

W P 2=0.0012692 m3 / kg(16500−4500) kPa

kJ
W P 2=15.2304
kg

 Solving Enthalpy at state point 14

h14 =W P 2+ h13

h14 =15.2304 kJ /kg+¿ 1121.9 kJ/kg

kJ
h14 =1137.1304
kg

 Finding for the value of Cp of the Exhaust Temperature (T 4=645° C=918 K ¿

T (° C CP (kJ/kg K)

)
600 1.214
645 x
700 1.239

x = CP g = 1.22525 kJ/kg K

 Solving for the Mass of the Steam

 h13−h12
[ (
mg C Pg ( T 4−T 5 )=ms ( h6−h14 ) − 1−
)
( h −h )
h9 −h12 8 7 ]
kg
m s =206.316405
s

 Solving for the part of the Mass of the Steam that flows to OFWH; m 1

h13−h12
(
m 1= 1− )
m
h 9−h12 s

1121.9−293.799681
(
m 1= 1−
3399.037908−293.799681 )
kJ / kg ( 206.316405 kg/ s )

kg
m 1=¿151.2962525
s

 Solving for the Work of Turbine

Work of Turbine=ms (h 6−h7)+(ms−m1)(h 8−h 9)+(ms−m1)( h 9−h10)

Work of Turbine=206.316405 kg /s (3473.95−2769.4)kJ /kg+(206.316405−151.2962525)kg /s( 3

Work of Turbine=97057.1584 kW

W pump m s
 Solving for the Actual Pump Work 1 W pump ,actual 1=
ŋp

4.569681 kJ /kg (206.316405 kg / s )

W pump ,actual 1=
0.84

W pump ,actual 1=1122.381138kW

  Solving for the Actual Pump Work 2

kg
15.2304 kJ /kg(206.316405 )
s
W pump ,actual 2=
0.84

W pump ,actual 2=3740.81116 kW

 Solving for the Total Pump Work

W pump ,total =W pump, actual 1 +W pump ,actual 2

( 1122.381138 kW +3740.81116 kW )
W pump ,total=
0.84

W pump ,total=5789.514641kW

 Solving for the Steam Work Net

SteamWork Net =W t −W pump ,total

SteamWork Net =97057.1584 kW −5789.514641 kW

SteamWork Net =91267.6438 kW

 Solving for the Overall Power Output

Overall Power Output =Steam Work Net +Gas TurbineOutput

Overall Power Output =91267.6438 kW +310000 kW

Overall Power Output =401267.6438 kW

 Solving for the Heat Added

 W net
Gross Efficiency=
Qa

310000 kW
0.35=
Qa

Qa=885714.2857 kW

 Solving for the Overall Efficiency

(W steam +W gas )
Overall Efficiency=
Qa

(91267.6438 kW +310000 kW )
Overall Efficiency= ×100 %
885714.2857 kW

Overall Efficiency=45.3044114 %

Design Option 3

GAS TURBINE

Specifications

Power Output = 215 MW

kJ
Heat Rate = 8780
kWh
 Gross Efficiency = 41%

kg
Exhaust Mass Flow = 724
s

Exhaust Temperature, T6 =872 K

Gas Intercooling Cycle

T1 = 27.3°C = 300.3 K

P1 = 101.325 kPa

rp = 20

Solution

 Solving for P4

P4
r p=
P1

P4
20=
101.325 kPa

P4 =2056.8325 kPa

 Solving for P2 and P3

P2=P3 =√ P1 P4

P2=P3 =√(101.325 kPa)( 2056.8325 kPa)

P2=P3 =455.9625 kPa

 Solving for pressure ratio of every stage

P2=P3 =√ P1 P4

P2=P3 =√(101.325 kPa)( 2056.8325 kPa)

P2=P3 =455.9625 kPa

 Solving for T2

T 2 P2 k−1
=( ) k
T 1 P1

T2 455.9635 kPa k−1

=( ) k
300.3 K 101.325 kPa

T 2=461.516762 K

 Solving for T4

T 3=T 1=300.3 K

T3 P2 k−1
k
=( )
T4 P1

k−1
300.3 K k
=(20)
T4

T 4=706.7701322 K

 Solving for T5

T4 T 5
=
T1 T6

706.7701322 K T5
=
300.3 K 872 K
 T 5 = 2052.292891 K

 Solving for Work of Turbine, WT

W T =m C p (T 5−T 6 )

kJ kg
W T =2.54 (724 )( 2052.292891−872) K
kg−K s

Q A = 802.4390244 MW

STEAM TURBINE

Specifications

Model = SST – 500 Inlet Temperature = 585°C

Power Output = 250 MW Condensing Pressure = 0.5 ba

Inlet Pressure = 180 bar

Topping Cycle

T1 = 27.3°C = 300.3 K rp = 20

P1 = 101.325 kPa T4 = 599°C = 872 K

Solution

 Solving for T3
T2 T3
=
T1 T4

706.7701322 K T4
=
300.3 K 872 K

T 3=2052.29289 K

 Solving for P2 and P3

P2=P3 =√ P1 P4

P2=P3 =√(101.325 kPa)( 2056.8325 kPa)

P2=P3 =455.9625 kPa

 At state point 8 (super-heated)

P8=19 MPa

T 8=565 ℃

From Steam Table, Table 3 @ 19 MPa

T (℃ ¿ S (kJ/kg-K) H (kJ/kg)
560 6.3872 32428.4
565 S8 H8
570 6.4217 3457.3

By Interpolation:

kJ
S8=6.40445
kg−K
 kJ
h8 =3442.85
kg

 At state point 9 (saturated vapor)

S8=S 9=19 MPa

From Steam Table, Table 2 @ 19 MPa

S (kJ/kg-K) T (℃ ¿ P (MPa) H (kJ/kg)

560 202.89 1.65 32428.4
565 T9 P9 H8
570 204.34 6.427 3457.3

By Interpolation:

T 9=203.7425463 ℃

kJ
h 9=2795.37037
kg

P9=1.679398148 MPa

 At state point 10 (super-heated)

P9=P10 =1.679398148 MPa

T 9=565 ℃

From Steam Table, Table 3 @ 1.65 MPa

T (℃ ¿ S (kJ/kg-K) H (kJ/kg)
560 7.6896 3603.7
565 S1.65 H1.65
580 7.7418 3648.2
 By Interpolation:

kJ
S1.65=7.7022
kg−K

kJ
h1.65 =3614.825
kg

From Steam Table, Table 3 @ 1.70 MPa

T (℃ ¿ S (kJ/kg-K) H (kJ/kg)
560 7.6749 3603.3
565 S1.70 H1.70
580 7.7276 3647.8

By Interpolation:

kJ
S1.70=7.688075
kg−K

kJ
h1.70 =3614.425
kg

From Steam Table, Table 3 @ 1.70 MPa

P (kPa ¿ S (kJ/kg-K) H (kJ/kg)

1.65 7.7022 3614.825
1.679398148 S10 H1.70
1.70 7.688075 3614.425

By Interpolation:

kJ
S10=7.61437558
kg−K
 kJ
h10=3614.237037
kg

 At state point 11 (super-heated)

kJ
S10=S11 =7.681437558
kg−K

P10=1.4 MPa @ catalogue of OHFW

From Steam Table, Table 3 @ 1.65 MPa

S (kJ/kg-K) T (℃ ¿ H (kJ/kg)
7.6896 520 3517.9
S1.65 T11 H11
7.7418 540 3561.8

By Interpolation:

T 11=528.3654059 ℃

kJ
h11 =3536.262066
kg

 At state point 12 (Saturated Vapor)

kJ
S10=S12=7.681437558
kg−K

kJ
From Steam Table, Table 2 @ 7.681437558
kg−K

S (kJ/kg-K) P (MPa ¿ T (℃ ¿ H (kJ/kg)

7.6876 0.038 74.64 2634.7
 7.681437558 P12 T12 H12
7.670 0.040 75.87 2636.8

By Interpolation:

P12=0.0387002775 MPa

T 12=75.07067066℃

kJ
h12=2635.435291
kg

 At state point 13 (Saturated Liquid)

P12=P13=0.0387002775 MPa

From Steam Table, Table 2 @ 0.0387002775 MPa

P (MPa ¿ S (kJ/kg-K) T (℃ ¿ H (kJ/kg)

0.038 1.0111 74.64 312.43
0.0387002775 S13 T13 H13
0.040 1.0259 75.87 317.58

By Interpolation:

kJ
S13=1.016285385
kg−K

T 12=T 13=75.07067066 ℃

kJ
h13=314.234374
kg

 At state point 14
 kJ
S13=S14 =1.016285385
kg−K

From Steam Table, Table 2 @ 0.0387002775 MPa

S (kJ/kg-K) v (m3/kg)
1.0111 1.0257
1.015285385 h14
1.0259 1.0265

By Interpolation:

−3 m3
V 14=1.025980291 x 10
kg

 Solving for Pump Work

W pump =PV

−3 m3 (
W pump =1.025980291 x 10 1400−3.87002775 ) kPa
kg

kJ
W pump =1.3966666686
kg

 Solving for h14

W pump =h 14−h13

kJ kJ
1.3966666686 x 10−3 =h14−314.234374
kg kg

kJ
h14 =314.2353967
kg

 At state point 15 (Saturated Liquid)

P15=1.40 MPa

kJ
h15=830.30
kg

T 15=195.07 ℃

−3 m3
V 15=1.1489 x 10
kg

 At state point 16

W pump =PV

−3 m3 (
W pump =1.1489 x 10 1600−1400 ) KPa
kg

kJ
W pump =0.22978
kg

 Solving for h16

W pump =h 16−h15

kJ kJ
2.2978 x 10−4 =h16 −830.30
kg kg

kJ
h16 =195.0702298
kg

 Solving for Mass of Steam, mS

W gas =W steam

m g (T 6−T 7 )(cp gas )=m s ( h 8−h16 +h 10 −h9 )

kg kJ
724 ( 599℃ −27.3℃ )=m s ( 3442.85−195.0702298+3614.23−2795 )
s kg
 kg
m s =238.1695303
s

 Solving for Inlet Mass Flow Rate, m1

h15−h14
m 1=1− ( h11 −h14 )
kJ kJ
830.30

( )
−314.2353967
kg kg
m1=1−
kJ kJ
3536.262066 −314.2353967
kg kg

kg
m 1=200.0224642
s

 Solving for Steam Work, WST

W st =m s ( h 8−h9 ) + m11 ( h 10−h11 ) +(m s −m11 ) ( h10−h12 )

kg kJ kg kJ
W st =238.16 ( 3442.85−2795.37 ) +200.0224642 ( 3614.237037−3536.262066 ) +39.14706605
s kg s kg

W st =208.1238818 MW

 Solving for Actual Pump 1 Work, WP1’

W PUMP∗ms
W P1'=
ηP

kJ kg
1.3966666686 ∗238.1695303
kg s
W P 1 '=
0.84

W P 1 ' =396.0041058 kW
  Solving for Actual Pump 1 Work, WP2’

W PUMP∗m s
W P 2 '=
ηP

kJ kg
0.22928 ∗238.1695303
kg s
W P 2 '=
0.84

W P 2 ' =650.0894042 kW

 Solving for Total Actual Pump Work, WP2’

W P ' =W P 2 −W P 1 '
'

W P ' =650.0894042 kW−396.0041058kW

 W P 2 ' =1046.09351kW Solving for Steam Net Work, WST

W ST =W P 2 −W P 1'
'

W ST =208.1238818 MW −1.04609351 MW

W ST =206.6629468 MW

 Solving for Total Work of the Gas and Steam Turbine, WNET

W NET =W ST + W ¿

W NET =329 MW +206.6629468 MW

W NET =421.6629468 MW
  Solving for Heat Added, QA

Power Output
Q A=
η¿

329 MW
Q A=
0.41

Q A = 802.4390244 MW

 Solving for Overall Efficiency, η overall

W NET
ηoverall =
QA

421.6629468 MW
ηoverall =
802.4390244 MW
 ηoverall =52.54766206 % CHAPTER IV

ECONOMIC ANALYSIS

This chapter presents the economic analysis of the design options for the proposed

715 MW Combined Cycle Power Plant including the capital expenses, operating expenses,

and the total project cost. The Net Present Value, Payback Period and Rate of Investment

will also be presented.

1.Capital Expenditures

This expense refers to the initial cost necessary to start the project. This expense

includes the cost of the land, installation of mechanical equipment and I & C Supply,

civil and structural cost, electrical cost and cost of the owner.

a. Land Costs

Our plant location is at Talisay, Calaca, Batangas. Our plant consumes a total land

area of 17 hectares. The land area that we utilize is in the industrial zone of Calaca and

it is also located near the sea for the easily transportation of fuel.

b. Mechanical Equipment and I&C Supply and Installation

This includes all the components of our plant including the gas turbine, steam

turbine, condensers, generators, different types of pump, electrical transformers,

switchgear, motor, control centers, switchyards, distributed control systems (DCS) and

instrumentation and electrical commodities such as wire, cable tray and lighting.

c. Civil and Structural Costs

It consists of all the expenses needed for the preparation of the plant site including

the construction expenses like materials, equipments, utilities, clearings, drainage

systems, roads, underground utilities, and installations. According to the “Power Plant
 Theory and Design” written by Potter, building cost is approximately 33% of the total

equipment cost.

d. Electrical Costs

This includes the electrical expenses necessary to run the whole power plant.

According to the book “Power Plant Theory and Design” by Potter, the cost of

electricity is approximately 20% of the total equipment costs.

e. Owner’s Cost

It is the cost necessary to bring the proposed project to its commercially operating

state. It comprises the cost of the all the plant studies which includes the

environmental and engineering studies. It also includes legal fees, management of

project, insurance costing and the taxes of the property during the construction phase.

It comprises 10% of the total equipment costs according to the “Power Plant Theory

and Design” by Potter.

2. Operations Expenditures

It comprises the expenditures necessary during the normal operation condition of

the plant. The operating expenses also includes the maintenance cost of the plant and

the cost of fuel utilized during the operation.

a. Fuel Cost

For the proposed combined cycle power plant, we are going to utilize natural gas as

our main fuel. In determining the total cost of the fuel, we are going to solve for the

annual fuel consumption and multiply it with the fuel rate per million metric British

Thermal Unit (MM Btu).

b. Fixed Operating and Maintenance Cost

 It comprises of all the cost necessary for maintaining the condition of the

power plant. It consists of the fees that involves the labor force like their monthly

salaries and bonuses. It also includes the plant support utilities, administrative

expenses, preventive routine and maintenance, and the structural maintenance.

c. Variable Operating and Maintenance Cost

This includes all the expenses that involves the water supply and its treatment

and disposal. This also includes the lubrication expenses and other consumable

supplies, purchase of power and the charges based on the demand. These expenses

depend and varies based on the state of electrical generation.

3. Economic Indicators

It is all the expenses that shows the indications necessary to check the running

state of the power plant. It shows the annual revenue, annual depreciation cost, the

net present value, the payback period of the plant and the plant’s rate of return.

a. Annual Revenue

This is the total amount of money generated by the electrical sales within a

whole year of production. In order to solve the actual income of the plant, we must

subtract the annual revenue with the total operating expenditures of the plant.

b. Annual Depreciation Cost

It is referring on the degrading value of the power plant within its useful life.

According to the book “Power System Engineering” by Rajput, a power plant’s

typical life span ranges from 25 to 30 years and about 5% of the total capital

expenditures is the salvage value of the power plant.

 c. Net Present Value

Based on the book the “Power Plant Engineering” by Morse, the usual rate of

investment is about 6.5%. The rate of investment is necessary to determine the net

present value of the all the design options of our plant.

d. Payback Period

it is the expected amount of time that the cash expenditures of the power plant

are recovered from the total income generated at the stated time.

e. Rate of Return

It is the total profit or income of the power plant within a given period of time.

ECONOMIC ANALYSIS FOR DESIGN OPTION 1

A. CAPITAL EXPENDITURES

 LAND COST

Our proposed 400 MW combined cycle power plant has a total area of

170,000 m2. The land area costs ₱3,000.00 per square meter.

Land Cost = Area (Cost/m2)

Land Cost = (170,000) (₱3,000.00)

𝐋𝐚𝐧𝐝 𝐂𝐨𝐬𝐭 = ₱ 510,000,000.00

The total cost of mechanical equipment utilized for our design option 1 of a 400

MW CCPP is shown in table 5. The table shows the total number of units per

equipment, the price per unit and the total cost per unit.
 Table 5
Mechanical Equipment

No. of Price/Unit Total Cost

Components
Units (Php) (Php)
Black Start System 1 29,435,520 29,435,520
Gas Turbine and
1 25,215,830,215 25,215,830,215
Generator Assembly
Heat Recovery Steam
1 620,079,550 620,079,550
Generator (HRSG)
Steam Turbine Units 1 630,654,000 630,654,000
Generator Step-up
1 371,450,000 371,450,000
Transformers
Transmission Voltage
1 571,833,750 571,833,750
Equipment
Boiler Feed Pump 1 943,700 943,700
Air-cooled Condenser 1 1,105,210,000 1,105,210,000
Condensate Pump 1 1,351,461 1,351,461
Instrumentation and
1 69,037,500 69,037,500
Control
Total 28,615,825,700

The table above shows that the mechanical equipment used the proposed design

has a total cost of Php 28,615,825,700.

 CIVIL AND STRUCTURAL COSTS

Building Costs = 0.33 (Equipment Costs)

Building Costs = 0.33 (Php 28,615,825,700)

Building Costs = Php 9,443,222,480

 ELECTRICAL COSTS

Electrical Costs = 0.20 (Equipment Costs)

Electrical Costs = 0.20 (Php 28,615,825,700)

Electrical Costs = Php 5,723,165,139

 OWNER COSTS

Owner Costs = 0.10 (Equipment Costs)

Owner Costs = 0.10 (Php 28,615,825,700)

Owner Costs = Php 2,861,582,570

Table 6 shows the summary of the total capital expenditures for design option 1.

It includes the cost of land, the cost of mechanical equipment, the civil and structural

costs, the electrical cost and the owner cost.

Table 6
Summary of Capital Expenditures

Expenses Total Cost

Land Cost Php 510,000,000
Mechanical Equipment Php 28,615,825,700
Civil and Structural Cost Php 9,443,222,480
Electrical Cost Php 5,723,165,139
Owner Cost Php 2,861,582,570
Total Php 47,153,795,880

The table above shows that the total capital expenditures have a total cost of Php

47,153,795,880. The cost of mechanical equipment has the highest cost of Php

28,615,825,700 while land cost has the lowest cost of Php 510,000,000.

B. OPERATION EXPENDITURES

 FUEL COST

Fuel Cost =

$ 2.02 PhP 50.50 1 MM Btu

x x x 324,125.9137 kW x 8760 hrs
MM Btu $ 1.00 293.071 kWh

Fuel Cost = Php 988,297,647.50

 Table 7 shows the total fixed operating expenditures for design option 1. It

includes the position of the employees, the quantity of employees and their labor

rate.

Table 7
Fixed Operating Cost

POSITION QUANTITY LABOR RATE (Php)

General Manager 1 6,558,173
Accountants 1 2,276,385
Admin Support 3 5,852,083
Business Manager 1 2,643,254
Contract Administration 1 2,460,704
Technical Manager 1 5,078,140
Performance Engineer 1 5,179,154
Instrumentation and Control Engineer 1 5,179,154
Gasification Engineer 1 5,179,154
Syn Gas Engineer 1 5,179,154
Assistant Manager 1 2,818,347
Asset Scheduler 1 2,511,021
Safety Specialist 1 3,449,596
Environment Specialist 1 2,499,643
Procurement Manager 1 2,635,767
Operation’s Manager 1 5,709,738
Maintenance Manager 1 5,369,457
EH & S Manager 1 4,491,487
Fuel and Bi-Product Manager 1 4,574,671
Storeroom Manager 1 2,820,971
Assistant Operation Manager 1 5,503,371
Maintenance Planner 2 7,557,617
Store Person 2 2,085,570
Operations Coordinator 2 7,661,760
CMMS Technician 1 2,712,407
HR Generalist 1 2,511,020
Mechanical Specialist 2 6,185,025
Billing Clerk 2 3,835,684
Plant Chemist 1 3,593,118
Lab Tech 2 4,378,473
Shift Supervisor 5 22,141,443
Control Operators 5 19,154,419
Auxiliary Operators 5 13,189,950
Control Operators (Gasifier) 12 45,970,617
Auxiliary Operators (Gasifier) 20 52,759,771
Auxiliary Operators (Water Treatment) 12 31,655,857
Plant Mechanics 8 23,972,991
Mechanical Supervisor 1 167,391,104
I&C/DCS Specialist 8 1,303,153,575
Contract Maintenance Supervisor 1 3,490,481
Electrical Supervisor 1 256,918,709
Total 116 2,121,862,015

Table 7 shows the total number of employees that are needed for the operation of
the proposed design project. It has a total of 116 employees and a total labor rate of Php

2,121,862,015.

Table 8 shows the total maintenance cost of design option 1. It includes the total

maintenance cost such as the parts and materials and the outside labor.

Table 8
Total Maintenance Cost

Maintenance Cost Annual Cost

Parts and Materials Php 858,532,500
Outside Labor Php 382,128,615
Total Php 1,240,661,115

The table above shows that the parts and materials has a total of Php

858,532,500 while the outside labor has a total of Php 382,128,615. The annual

maintenance cost has a total cost of Php 1,240,661,115.

Table 9 shows the summary of the Fixed Operating Cost. It includes the total

cost of labor and the total maintenance cost of the proposed design option 1.

Table 9
Summary of Fixed Operating Cost

Fixed Operating Cost Total Costs

Labor Cost Php 2,121,862,015
Maintenance Cost Php 1,240,661,115
Total Php 3,362,523,130

The table above shows that the labor cost has a total cost of Php 2,121,862,015

and maintenance cost has a total cost of Php 1,240,661,115. Fixed operating cost has a

total cost Php 3,362,523,130.

Table 10 shows the summary of the fixed operating cost, it includes the different

consumables and its respective annual cost.

Table 10
 Variable Operating Cost

CONSUMABLES ANNUAL COST (Php)

Gas Catalyst 205,242,401
Water Treatment Consumables 58,642,325
Power Block Consumables 15,495,332
TOTAL 279,380,058

The table above shows that the gas catalyst has a total annual cost of Php

205,242,401, the water treatment consumables has a total annual cost of Php 58,642,325

and the power block consumables has a total annual cost of $306,838. The total variable

operating cost has a total annual cost of Php 279,380,058.

Table 11 shows the summary of the total operating expenditures, it includes the

total cost of fuel consumption, the variable operating cost and the fixed operating cost

Table 11
Summary of Operating Expenditures

Operating Expenditures Total Costs

Fuel Cost Php 988,297,647.50
Fixed Operating Costs Php 3,362,523,130
Variable Operating Cost Php 279,380,058
Total Php 4,630,200,836

The table above shows the total operating expenditures with a total cost of Php

4,630,200,836.

C. Economic Indicators

 Annual Revenue

kW
Annual Revenue = Php 8.2733 x (324,125.9137 kW * 0.925) (8760 hr)
hr

Annual Revenue = Php 21,728,931,240

  Annual Cost

Capital Expenditures - Salvage Value

Annual Plant
Depreciation = Useful Life

Php 47,153,795,880- (0.05) (Php 47,153,795,880)

Annual Plant
Depreciation = 25
Annual Plant Depreciation = Php 1,791,844,243

 Net Present Value

Net Present Worth = Cash inflows - Cash outflows Cash inflows = Revenuep+

Salvage Valuep

1−1.065−25
Cash inflows = (Php 21,728,931,240 x ¿+(Php 2,357,689,794)( 1.065)-25
0.065

Cash inflows = Php 265,535,191,800

Cash outflow = Capital + Operating costp

1−1.065−25
Cash outflow = Php 47,153,795,880+ Php 4,630,200,836 ( ¿
0.065

Cash outflow = Php 103,632,414,9

Net Present Worth = Php 265,535,191,800 - Php 103,632,414,900

Net Present Worth = Php 161,902,776,900

Payback Period

Payback Period =
Capital Expenditures - Salvage Value Cash inflow per Period
Payback Period

Capital Expenditures - Salvage Value

Payback
Period = Cash inflow per Period
 1−1.05−25
Operatingp = of Php 4,630,200,836 ( ¿
0.05

Operatingp = Php 65,257,793,910

Cash outflows =Php 988,297,647.50 + Php 65,257,793,910

Cash outflows = Php 66,246,091,560

 Net Present Value

Net Present Value = Cash Inflows – Cash Outflows

Net Present Value = Php 306,942,584,700 - Php 66,246,091,560

Net Present Value = Php 240,696,493,100

ECONOMIC ANALYSIS FOR DESIGN OPTION 2

A. CAPITAL EXPENDITURES

 LAND COST

Our proposed 400 MW combined cycle power plant has a total area of

170,000 m2. The land area costs ₱3,000.00 per square meter.

Land Cost = Area (Cost/m2)

Land Cost = (170,000) (₱3,000.00)

𝐋𝐚𝐧𝐝 𝐂𝐨𝐬𝐭 = ₱ 510,000,000.00

The total cost of mechanical equipment utilized for our design option 2 of a 400

MW CCPP is shown in table 12. The table shows the total number of units per

equipment, the price per unit and the total cost per unit.
 Table 12
Mechanical Equipment

No. of Price/Unit Total Cost

Components
Units (Php) (Php)
Black Start System 1 28,525,650 28,525,650
Gas Turbine and
1 24,205,770,258 24,205,770,258
Generator Assembly
Heat Recovery Steam
1 620,079,550 620,079,550
Generator (HRSG)
Steam Turbine Units 1 630,654,000 630,654,000
Generator Step-up
1 371,450,000 371,450,000
Transformers
Transmission Voltage
1 571,833,750 571,833,750
Equipment
Boiler Feed Pump 1 943,700 943,700
Open Feed Water Heater 1 2,983,930 2,983,930
Air-cooled Condenser 1 1,105,210,000 1,105,210,000
Condensate Pump 1 1,351,461 1,351,461
Instrumentation and
1 69,037,500 69,037,500
Control
Total 27,617,839,799

From the table above, mechanical equipment used the proposed design has a total

of Php 27,617,839,799.

 CIVIL AND STRUCTURAL COSTS

Building Costs = 0.33 (Equipment Costs)

Building Costs = 0.33 (Php 27,617,839,799)

Building Costs = Php 9,113,887,133.67

 ELECTRICAL COSTS

Electrical Costs = 0.20 (Equipment Costs)

Electrical Costs = 0.20 (Php 27,617,839,799)

 Electrical Costs = Php 5,523,567,959.80

 OWNER COSTS

Owner Costs = 0.10 (Equipment Costs)

Owner Costs = 0.10 (Php 27,617,839,799)

Owner Costs = Php 2,761,783,979.90

Table 13 shows the summary of the total capital expenditures for design option

2. It includes the cost of land, the cost of mechanical equipment, the civil and structural

costs, the electrical cost and the owner cost.

Table 13
Summary of Capital Expenditures

Expenses Total Cost

Land Cost Php 510,000,000
Mechanical Equipment Php 27,617,839,799
Civil and Structural Cost Php 9,113,887,133.67
Electrical Cost Php 5,523,567,959.80
Owner Cost Php 2,761,783,979.90
Total Php 45,017,078,872.37

The table above shows that the total capital expenditures have a total cost of Php

45,017,078,872.37. The cost of mechanical equipment has the highest cost of Php

27,617,839,799 while land cost has the lowest cost of Php 510,000,000.

B. OPERATION EXPENDITURES

 FUEL COST

Fuel Cost =

$ 2.02 PhP 50.50 1 MM Btu

x x x 401267.6438 kW x 8760 hrs
MM Btu $ 1.00 293.071 kWh
 Fuel Cost = Php 1,223,511,764

Table 14 shows the total fixed operating expenditures for design option 2. It

includes the position of the employees, the quantity of employees and their labor

rate.

Table 14
Fixed Operating Cost

POSITION QUANTITY LABOR RATE (Php)

General Manager 1 6,558,173
Accountants 1 2,276,385
Admin Support 3 5,852,083
Business Manager 1 2,643,254
Contract Administration 1 2,460,704
Technical Manager 1 5,078,140
Performance Engineer 1 5,179,154
Instrumentation and Control Engineer 1 5,179,154
Gasification Engineer 1 5,179,154
Syn Gas Engineer 1 5,179,154
Assistant Manager 1 2,818,347
Asset Scheduler 1 2,511,021
Safety Specialist 1 3,449,596
Environment Specialist 1 2,499,643
Procurement Manager 1 2,635,767
Operation’s Manager 1 5,709,738
Maintenance Manager 1 5,369,457
EH & S Manager 1 4,491,487
Fuel and Bi-Product Manager 1 4,574,671
Storeroom Manager 1 2,820,971
Assistant Operation Manager 1 5,503,371
Maintenance Planner 2 7,557,617
Store Person 2 2,085,570
Operations Coordinator 2 7,661,760
CMMS Technician 1 2,712,407
HR Generalist 1 2,511,020
Mechanical Specialist 2 6,185,025
Billing Clerk 2 3,835,684
Plant Chemist 1 3,593,118
Lab Tech 2 4,378,473
Shift Supervisor 5 22,141,443
Control Operators 5 19,154,419
Auxiliary Operators 5 13,189,950
Control Operators (Gasifier) 12 45,970,617
Auxiliary Operators (Gasifier) 20 52,759,771
Auxiliary Operators (Water Treatment) 12 31,655,857
Plant Mechanics 8 23,972,991
Mechanical Supervisor 1 167,391,104
I&C/DCS Specialist 8 1,303,153,575
Contract Maintenance Supervisor 1 3,490,481
Electrical Supervisor 1 256,918,709
Total 116 2,121,862,015
 Table 14 shows the total number of employees that are needed for the operation

of the proposed design project. It has a total of 116 employees and a total labor rate of

Php 2,121,862,015.

Table 15 shows the total maintenance cost of design option 2. It includes the

total maintenance cost such as the parts and materials and the outside labor.

Table 15
Total Maintenance Cost

Maintenance Cost Annual Cost

Parts and Materials Php 978,524,500
Outside Labor Php 369,128,716
Total Php 1,347,653,216

The table above shows that the parts and materials has a total of Php

978,524,500while the outside labor has a total of Php 369,128,716. The annual

maintenance cost has a total cost of Php 1,347,653,216.

Table 16 shows the summary of the Fixed Operating Cost. It includes the total

cost of labor and the total maintenance cost of the proposed design option 2.

Table 16
Summary of Fixed Operating Cost

Fixed Operating Cost Total Costs

Labor Cost Php 2,121,862,015
Maintenance Cost Php 1,347,653,216
Total Php 3,469,515,231

The table above shows that the labor cost has a total cost of Php 2,121,862,015

and maintenance cost has a total cost of Php 1,347,653,216. Fixed operating cost has a

total cost Php 3,469,515,231.

Table 17 shows the summary of the fixed operating cost, it includes the different

consumables and its respective annual cost.

 Table 17
Variable Operating Cost

CONSUMABLES ANNUAL COST (Php)

Gas Catalyst 205,242,401
Water Treatment Consumables 58,642,325
Power Block Consumables 15,495,332
TOTAL 279,380,058

The table above shows that the gas catalyst has a total annual cost of Php

205,242,401, the water treatment consumables has a total annual cost of Php 58,642,325

and the power block consumables has a total annual cost of $306,838. The total variable

operating cost has a total annual cost of Php 279,380,058.

Table 18 shows the summary of the total operating expenditures, it includes the

total cost of fuel consumption, the variable operating cost and the fixed operating cost

Table 18
Summary of Operating Expenditures

Operating Expenditures Total Costs

Fuel Cost Php 1,223,511,764
Fixed Operating Costs Php 3,469,515,231
Variable Operating Cost Php 279,380,058
Total Php 4,972,407,053

The table above shows the total operating expenditures with a total cost of Php

4,972,407,053.

C. Economic Indicators

 Annual Revenue

kW
Annual Revenue = Php 8.2733 x (401267.6438 kW * 0.925) (8760 hr)
hr
Annual Revenue = Php 26,900,400,960
  Annual Cost

Capital Expenditures - Salvage Value

Annual Plant
Depreciation = Useful Life

Php 45,017,078,872.37- (0.05) (Php

Annual Plant 45,017,078,872.37)
Depreciation =
25
Annual Plant Depreciation = Php
1,910,648,997.00

 Net Present Value

Net Present Worth = Cash inflows - Cash

outflows Cash inflows = Revenuep +

Salvage Valuep

Cash inflows = (Php 26,900,400,960 x

1−1.065−25
¿+( Php 2,250,853,944)( 1.065)-25
0.065

Cash inflows = Php 328,594,012,200

Cash outflow = Capital + Operating costp

1−1.065−25
Cash outflow = Php 45,017,078,872.37 + Php 4,972,407,053 ( ¿
0.065

Cash outflow = Php 105,669,887,100

Net Present Worth = Php 328,594,012,200 - Php 105,669,887,100

 Net Present Worth = Php 222,924,125,100

 Payback Period

Capital Expenditures - Salvage Value

Payback
Period = Cash inflow per Period

Php 45,017,078,872.37 - (0.05) (Php 45,017,078,872.37)

Payback
Period = Php 26,900,400,960 - Php 4,972,407,053

Payback Period = 1.950302664 years

Payback Period = 2 years

 Rate of Return

Net Annual Profit

Rate of x 100 %
Capital Expenditure
Return
=

Php 26,900,400,960 - Php 4,972,407,053

Rate of x 100 %
Php 45,017,078,872.37
Return
=

Rate of Return = 48.71038827%

 Sensitivity Analysis

1-1.05-25
Revenuep = Php )
0.05
26,900,400,960 (

Revenuep = Php 379,132,759,900

Salvage
p
Value = Php 2,250,853,944(1.05)-

25
Salvage Valuep = Php 664,683,408.20
Cash inflows = Revenuep + Salvage

Valuep

Cash inflows = Php 379,132,759,900+ Php 664,683,408.20

Cash inflows = Php 379,797,443,300

1−1.05−25
Operatingp = Php 4,972,407,053 ( ¿
0.05

Operatingp = Php 70,080,829,360

 Cash outflows = Php 3,035,813,648 + Php

70,080,829,360

Cash outflows = Php 73,116,643,010

 Net Present Value

Net Present Value = Cash Inflows – Cash Outflows

Net Present Value = Php 379,797,443,300- Php 70,080,829,360

Net Present Value = Php

309,716,613,900