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Handbook For Cogeneration and Combined Cycle Power Plants: Second Edition

This document is the preface and table of contents for the second edition of the Handbook for Cogeneration and Combined Cycle Power Plants by Meherwan P. Boyce. The preface dedicates the book to the author's grandfather and his contributions to engineering and power development in India and Pakistan. The table of contents provides an overview of the chapters to come, including chapters on an overview of power generation technologies like cogeneration, combined cycles, and integrated gasification combined cycles. It also outlines chapters on cycles for cogeneration and combined cycle plants.

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0% found this document useful (0 votes)
215 views18 pages

Handbook For Cogeneration and Combined Cycle Power Plants: Second Edition

This document is the preface and table of contents for the second edition of the Handbook for Cogeneration and Combined Cycle Power Plants by Meherwan P. Boyce. The preface dedicates the book to the author's grandfather and his contributions to engineering and power development in India and Pakistan. The table of contents provides an overview of the chapters to come, including chapters on an overview of power generation technologies like cogeneration, combined cycles, and integrated gasification combined cycles. It also outlines chapters on cycles for cogeneration and combined cycle plants.

Uploaded by

setyo nugroho
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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CYCLE POWER PLANTS
FOR COGENERATION
AND COMBINED

Dr. Meherwan P. Boyce, P.E.


HANDBOOK

Second Edition
© 2010, ASME, 3 Park Avenue, New York, NY 10016, USA (www.asme.org)

All rights reserved. Printed in the United States of America. Except as permitted
under the United States Copyright Act of 1976, no part of this publication may be
reproduced or distributed in any form or by any means, or stored in a database or
retrieval system, without the prior written permission of the publisher.

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INFORMATION CONTAINED IN THIS WORK HAS BEEN OBTAINED BY
THE AMERICAN SOCIETY OF MECHANICAL ENGINEERS FROM SOURCES
BELIEVED TO BE RELIABLE. HOWEVER, NEITHER ASME NOR ITS
AUTHORS OR EDITORS GUARANTEE THE ACCURACY OR COMPLETENESS
OF ANY INFORMATION PUBLISHED IN THIS WORK. NEITHER ASME
NOR ITS AUTHORS AND EDITORS SHALL BE RESPONSIBLE FOR ANY
ERRORS, OMISSIONS, OR DAMAGES ARISING OUT OF THE USE OF THIS
INFORMATION. THE WORK IS PUBLISHED WITH THE UNDERSTANDING
THAT ASME AND ITS AUTHORS AND EDITORS ARE SUPPLYING
INFORMATION BUT ARE NOT ATTEMPTING TO RENDER ENGINEERING
OR OTHER PROFESSIONAL SERVICES. IF SUCH ENGINEERING OR
PROFESSIONAL SERVICES ARE REQUIRED, THE ASSISTANCE OF AN
APPROPRIATE PROFESSIONAL SHOULD BE SOUGHT.

ASME shall not be responsible for statements or opinions advanced in papers or . . .


printed in its publications (B7.1.3). Statement from the Bylaws.

For authorization to photocopy material for internal or personal use under those
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Library of Congress Cataloging-in-Publication Data

Boyce, Meherwan P.
Handbook for cogeneration and combined cycle power plants /
Meherwan P. Boyce. — 2nd ed..
p. cm.
Includes bibliographical references and index.
ISBN 978-0-7918-5953-7 (alk. paper)
1. Cogeneration of electric power and heat. 2. Combined cycle power plants.
I. Title.
TK1041.B68 2010
621.1’99–dc22 2009043330
This book is dedicated to my
Grandfather
Khan Bahdur Jehangir R. Colabawala MBE
(1885–1975)
His dedication to engineering and

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his achievements in bringing power to
India and Pakistan
has been the inspiration that has
guided me through my entire career
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TABLE OF CONTENTS

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DEDICATION iii

PREFACE xv

1. AN OVERVIEW OF POWER GENERATION 1

Distributed Generation .............................................................................. 17


Diesel and Gasoline Engines ................................................................... 21
Natural Gas Reciprocating Engines ...................................................... 21
Gas Turbines . ........................................................................................... 21
Micro-Turbines ....................................................................................... 22
Fuel Cell Technology ............................................................................... 23
Solar Energy-Photovoltaic Cells ............................................................ 27
BioMass Systems ....................................................................................... 27
Wind Energy ............................................................................................ 27
Cogeneration .............................................................................................. 29
Cogeneration Qualifications ................................................................... 34
Gas Turbine Cycle in Cogeneration Mode . .......................................... 35
Combined Cycle Plants ................................................................................. 39
Availability and Reliability .......................................................................... 44
Properties of Gas Turbine Exhaust ............................................................. 46
Steam Generation Calculations .............................................................. 47
Gas Turbine Heat Recovery .......................................................................... 47
Supplementary Firing of Heat Recovery Systems ..................................... 50
Environmental Effects ............................................................................. 50
Integrated Gasifier Combined Cycle Plants .................................................. 50
Air Separation Unit .................................................................................... 53
Residual Nitrogen Injection ....................................................................... 53
Coal Gasifiers .............................................................................................. 54
Carbon Capture and Sequestration . ......................................................... 57
IGCC Plants — Commercial and Proposed Plants . .................................... 59
vi • COGENERATION AND COMBINED CYCLE POWER PLANTS

2. CYCLES 61

Combined Cycle Plant Operation ............................................................... 61


The Brayton Cycle ....................................................................................... 61
Inlet Cooling Effect . ................................................................................ 63
Regeneration Effect . ............................................................................ 70
Increasing the Work Output of the Simple Cycle Gas
Turbine ..................................................................................................... 74
Intercooling and Reheat Effects ............................................................. 75

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Injection of Compressed Air, Steam, or Water
for Increasing Power ............................................................................... 77
Combination of Evaporative Cooling and Steam
Injection ................................................................................................... 81
Advanced Gas Turbine Cycles .................................................................... 81
Compressed Air Energy Storage Cycle . .................................................. 81
Actual Cycle Analysis ................................................................................... 84
The Simple Cycle ..................................................................................... 84
The Split-Shaft Simple Cycle . .................................................................. 86
The Regenerative Cycle ........................................................................... 87
The Intercooled Simple Cycle .................................................................. 89
The Reheat Cycle ..................................................................................... 89
The Intercooled Regenerative Reheat Cycle .......................................... 91
The Steam Injection Cycle ....................................................................... 91
The Evaporative Regenerative Cycle .................................................. 100
The Brayton-Rankine Cycle ................................................................... 100
Summation of Cycle Analysis ................................................................... 104
A General Overview of Combined Cycle Plants ........................................ 104

3. PERFORMANCE AND MECHANICAL EQUIPMENT STANDARDS 117

Major Variables of a Combined Cycle Power Plant ................................. 119


Plant Location and Site Configuration .............................................. 119
Plant Type ........................................................................................... 122
Plant Size and Efficiency ...................................................................... 122
Type of Fuel .......................................................................................... 128
Types of HRSG . ..................................................................................... 128
Types of Condensers ............................................................................ 129
Enclosures .............................................................................................. 130
Plant Operation Mode: Base or Peaking ............................................. 130
Start-up Techniques . ............................................................................ 131
Performance Standards ........................................................................... 131
ASME, Performance Test Code on Overall Plant Performance............ 131
ASME, Performance Test Code on Test Uncertainty: Instruments
and Apparatus ...................................................................................... 132
ASME, Performance Test Code on Gas Turbines . ............................... 132
TABLE OF CONTENTS • vii

ASME, Performance Test Code on Gas Turbine Heat Recovery


Steam Generators ............................................................................... 133
ASME, Performance Test Code on Steam Turbines .......................... 134
ASME, Performance Test Code on Steam Condensing
Apparatus . ............................................................................................ 134
ASME, Performance Test Code on Atmospheric Water Cooling
Equipment . .......................................................................................... 135
ISO, Natural Gas — Calculation of Calorific Value, Density
and Relative Density .............................................................................. 135

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Table of Physical Constants of Paraffin Hydrocarbons . .................... 135
Mechanical Parameters ............................................................................ 136
API Std 616, Gas Turbines for the Petroleum, Chemical
and Gas Industry Services ...................................................................... 136
API Std 618, Reciprocating Compressors for Petroleum,
Chemical and Gas Industry Services ...................................................... 138
API Std 619, Rotary-Type Positive Displacement Compressors
for Petroleum, Chemical, and Gas Industry Services . ........................ 138
API Std 613 Special Purpose Gear Units for Petroleum,
Chemical and Gas Industry Services ...................................................... 138
API Std 677, General-Purpose Gear Units for Petroleum,
Chemical and Gas Industry Services ...................................................... 139
API Std 614 , Lubrication, Shaft-Sealing, and Control-Oil
Systems and Auxiliaries for Petroleum, Chemical and
Gas Industry Services .............................................................................. 139
ANSI/API Std 610 Centrifugal Pumps for Petroleum,
Heavy Duty Chemical and Gas Industry Services . .............................. 139
API Publication 534, Heat Recovery Steam Generators . ..................... 140
API RP 556, Fired Heaters & Steam Generators ................................. 140
ISO 10436:1993 Petroleum and Natural Gas
Industries — General Purpose Steam Turbine for
Refinery Service ..................................................................................... 140
API Std 671, Special Purpose Couplings for Petroleum
Chemical and Gas Industry Services ...................................................... 140
ANSI/API Std 670 Vibration, Axial-Position, and
Bearing-Temperature Monitoring Systems .......................................... 140
API Std 672, Packaged, Integrally Geared Centrifugal Air
Compressors for Petroleum, Chemical, and Gas
Industry Services .................................................................................. 141
API Std 681, Liquid Ring Vacuum Pumps and Compressors .............. 141
Gas Turbine ............................................................................................... 141
Gears ............................................................................................................ 146
Lubrication Systems ................................................................................... 148
Vibration Measurements ........................................................................... 149
Specifications ............................................................................................ 151
viii • COGENERATION AND COMBINED CYCLE POWER PLANTS

4. AN OVERVIEW OF GAS TURBINES 155

Industrial Heavy-Duty Gas Turbines ......................................................... 165


Aircraft-Derivative Gas Turbines ............................................................... 168
Medium-Range Gas Turbines . ................................................................. 169
Small Gas Turbines ..................................................................................... 170
Major Gas Turbine Components . .............................................................. 173
Compressors . .......................................................................................... 173
Regenerators . ....................................................................................... 189

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Combustors ..................................................................................... 190
Combustor Design Considerations.......................................................... 194
Typical Combustor Arrangements.......................................................... 195
Air Pollution Problems............................................................................. 196
Dry Low NOx Combustor......................................................................... 201
Catalytic Combustion............................................................................... 208
Features of Catalytic Combustion........................................................... 208
Catalytic Combustor Design.................................................................... 211
Turbine Expander Section............................................................................ 212
Radial-Inflow Turbine.............................................................................. 214
Mixed-Flow Turbine................................................................................. 215
Axial-Flow Turbines................................................................................. 215
Impulse Turbine....................................................................................... 219
The Reaction Turbine.............................................................................. 222
Turbine Blade Cooling Concepts............................................................. 225
Turbine Blade Cooling Design................................................................ 227
Cooled-Turbine Aerodynamics................................................................ 231
Instrumentation and Controls.......................................................................................237

5. AN OVERVIEW OF STEAM TURBINES 239

Introduction................................................................................................. 239
Non-Condensing Cycle............................................................................ 239
Condensing Cycle.................................................................................... 239
The Rankine Cycle........................................................................................ 240
Heat Rate and Steam Rate.....................................................................243
Turbine Component Efficiency..............................................................243
Mechanical Efficiency.............................................................................244
The Regenerative - Reheat Cycle...........................................................244
Steam Turbine.........................................................................................246
Classifications of Steam Turbines........................................................... 247
Steam Flow Directions............................................................................ 247
Steam Passage Between Blades............................................................. 249
Turbine Stages in Series.......................................................................... 249
Single-Stage or Simple-Impulse Turbine............................................... 250
Multistage Impulse-Type Turbine.......................................................... 251
Velocity and Pressure Stage Combination............................................ 251
TABLE OF CONTENTS • ix

Velocity-Stage, Curtis-Type Impulse Turbine........................................ 251


Pressure-Stage, Rateau-Type Impulse Turbine...................................... 251
Arc of Peripheral Admission to the Total Circumference..................... 254
General Flow Arrangement................................................................... 258
Single-Flow Single Casing Turbines....................................................... 259
Extraction Flow Turbine......................................................................... 259
Compound-Flow or Tandem Compound Turbine................................. 260
Cross Compound Turbine....................................................................... 260
Double-Flow Turbines............................................................................ 261

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Steam Turbine Characteristics................................................................ 261
Features and Structure of Large Steam Turbines in Combined
Cycle Plant Application............................................................................... 262
Features and Structure of HP and IP Nozzles and Blades......................... 263
HP and IP Nozzle Diaphragms................................................................ 266
Blades...................................................................................................... 268
Blade Attachments................................................................................. 271
Features and Structure of LP Blades........................................................... 272
Gland Seal System........................................................................................ 276
Interstage Seals....................................................................................... 277
End Seals.................................................................................................. 277
Required Material Characteristics............................................................... 278
Blade Materials............................................................................................ 280
Surface Treatments...................................................................................... 282
Steam Turbine Performance....................................................................... 282
Change in Main Steam Temperature.................................................... 286
Change in Main Steam Pressure............................................................ 288
Change in Steam Flow............................................................................ 288
Change in Reheat Steam Temperature................................................. 288
Change in Reheat Steam Pressure......................................................... 288
Change in Condenser Back Pressure...................................................... 293
Change due to Operational Hours........................................................ 295
Change in Power Factor......................................................................... 295

6. AN OVERVIEW OF PUMPS 297

Range of Operation................................................................................. 297


Pump Selection........................................................................................ 301
Pump Materials........................................................................................ 302
Types of Pumps............................................................................................. 305
Process Pumps..................................................................................................... 305
Sump Pumps............................................................................................. 305
Axial-Flow Pumps..................................................................................... 306
Turbine Pumps......................................................................................... 306
Regenerative Pumps................................................................................ 306
Gear Pumps.............................................................................................. 307
Screw Pumps............................................................................................ 307
 • COGENERATION AND COMBINED CYCLE POWER PLANTS

Centrifugal Pumps................................................................................... 307


Pump Application in Combined Cycle Power Plants.................................. 312
The IP-LP Circulating Pump..................................................................... 312
HP Feed Water Pumps............................................................................. 313
The HP Circulating Pump......................................................................... 314
Condenser Pumps.................................................................................... 314
Cooling Water Pumps.............................................................................. 314
Lubrication Pumps................................................................................... 314
Fuel Pumps............................................................................................... 315

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7. HEAT RECOVERY STEAM GENERATORS 317

Introduction ................................................................................................317
Design Considerations . ..............................................................................320
Multipressure Steam Generators ..........................................................320
Off-Design Performance .......................................................................322
Construction of the HRSG .....................................................................323
Casing of the HRSG . ..............................................................................324
Forced-Circulation System .....................................................................324
Back-Pressure Considerations (Gas Side) ..............................................324
Finned Tubing ........................................................................................324
Tube Materials .......................................................................................324
HRSG Design Requirements ..................................................................325
Economizers ...........................................................................................326
Evaporators ............................................................................................327
Attemperators .......................................................................................329
Desuperheaters ......................................................................................330
Deaerator ....................................................................................................333
Supplementary Firing of Heat Recovery Systems . ...............................335
Design Features .....................................................................................338
Once Through Steam Generators .........................................................342
HRSG Operational Characteristics . .......................................................344
HRSG Effectiveness ................................................................................346
Water Chemistry ....................................................................................346
Water Treatment Plants ........................................................................348
Chemical Storage and Dosing ...............................................................352
HRSG Chemical Cleaning .......................................................................352
Vibration and Noise . .............................................................................356
Filter Housing, Duct Work, and Insulation . .........................................357
Diverters, Silencers, and Burners ..........................................................360
HRSG Reliability and Durability ............................................................365

8. CONDENSERS AND COOLING TOWERS 367

Condensers .................................................................................................. 367


Types of Condensers .............................................................................. 369
TABLE OF CONTENTS • xi

Condensate Polisher Systems ................................................................ 371


Available Condensate Polisher Technology .......................................... 376
Condenser Fouling ...................................................................................... 381
Cooling Towers . ..................................................................................... 383
Design of Cooling Towers ..................................................................... 385
Chemical Water Treatment for Cooling Towers ....................................... 389
Cooling Tower Biological Control . ....................................................... 390
Cooling Tower Scale Control ................................................................. 390
Dispersants . ............................................................................................ 391

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Corrosion Inhibitors ............................................................................... 391
Development of a Cooling Tower Treatment Program ...................... 392

9. GENERATORS, MOTORS AND SWITCH GEARS 395

Motors ........................................................................................................ 395


Constant Speed Motors ........................................................................ 396
Alternating Current Squirrel-Cage Induction Motors ...................... 396
Synchronous Alternating-Current Motors .......................................... 397
Power-Factor Correction ...................................................................... 398
Generator . ............................................................................................... 399
Design Characteristics . ........................................................................ 402
Switchgear ............................................................................................... 417
Electrical Single Line Diagram .................................................................. 423

10. FUELS, FUEL PIPING AND FUEL STORAGE 425

Fuel Specifications ................................................................................... 427


Fuel Properties ......................................................................................... 430
Heavy Fuels ................................................................................................ 442
Cleaning of Turbine Components ............................................................ 446
Turbine Wash ........................................................................................ 446
Compressor Washing ............................................................................ 448
Fuel Economics .......................................................................................... 449
Heat Tracing of Piping Systems ................................................................ 450
Types of Heat-Tracing Systems ............................................................ 452
Choosing the Best Tracing System ....................................................... 458
Storage of Liquids ................................................................................... 459
Atmospheric Tanks ............................................................................. 459
Elevated Tanks ...................................................................................... 460
Open Tanks ......................................................................................... 460
Fixed Roof Tanks . ................................................................................. 460
Floating Roofs Tanks ............................................................................ 461
Pressure Tanks . ..................................................................................... 461
Calculation of Tank Volume ................................................................ 461
Container Materials, Insulation and Support .................................... 464
xii • COGENERATION AND COMBINED CYCLE POWER PLANTS

11. BEARINGS, SEALS AND LUBRICATION SYSTEMS 467

Bearings ..................................................................................................... 467


Rolling Bearings .................................................................................... 467
Journal Bearings ................................................................................. 474
Thrust Bearings .................................................................................... 482
Seals ........................................................................................................... 486
Non-contacting Seals .......................................................................... 487
Lubrication Oil System . ............................................................................. 492

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Lubricant Selection .............................................................................. 497
Oil Sampling and Testing ..................................................................... 497
Oil Contamination ................................................................................ 498
Filter Selection ...................................................................................... 498
Cleaning and Flushing ........................................................................ 500
Coupling Lubrication .......................................................................... 501
Lubrication Management Program .................................................... 502

12. CONTROL SYSTEMS AND CONDITION MONITORING 505

Control Systems ....................................................................................... 505


Condition Monitoring Systems ................................................................. 516
Identification of Losses in a Combined
Cycle Power Plants . ............................................................................ 518
The Gas Turbine .................................................................................. 518
HRSG ....................................................................................................... 521
Steam Turbine . ..................................................................................... 522
Condenser ........................................................................................... 522
Design of a Condition-Monitoring System ............................................ 524
Monitoring Software . ........................................................................ 525
Implentation of a Condition-Monitoring System .................................. 527
Plant Power Optimization . ....................................................................... 529
Life Cycle Costs ........................................................................................... 531

13. PERFORMANCE TESTING OF COMBINED CYCLE POWER PLANT 535

Gas Turbine ............................................................................................. 538


Air Inlet Filter Module ....................................................................... 539
Compressor Module . ......................................................................... 539
Combustor Module . ............................................................................ 541
Expander Module .............................................................................. 541
Life Cycle Consideration of Various Critical Hot-Section
Components ......................................................................................... 541
HRGS Calculations Module . ................................................................... 542
Steam Turbine Calculations ..................................................................... 544
TABLE OF CONTENTS • xiii

Condenser Calculations ............................................................................ 546


Performance Curves . ................................................................................ 546
Performance Computations ................................................................... 548
General Governing Equations . ......................................................... 549
Gas-Turbine Performance Calculation . .............................................. 554
Heat-Recovery Steam Generator ........................................................ 564
Steam Turbines ........................................................................................... 567
Plant Losses .......................................................................................... 571
Nomenclature ........................................................................................... 572

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14. MAINTENANCE TECHNIQUES 575

Philosophy of Maintenance ...................................................................... 575


Maximization of Equipment Efficiency and Effectiveness .................... 577
Organization Structures ............................................................................ 580
Performance-Based Total Productive Maintenance Program .......... 580
Implementation of a Performance-Based Total Productive
Maintenance ....................................................................................... 580
Maintenance Department Requirements ......................................... 583
Spare Parts Inventory ......................................................................... 588
Inspections ........................................................................................... 589
Condition and Life Assessment .......................................................... 589
Redesign for Higher Machinery Reliability ........................................ 590
Maintenance Scheduling . .................................................................. 598
Maintenance Communications ............................................................ 599

15. COMBINED CYCLE POWER PLANT PROBLEMS 603

Gas Turbines ............................................................................................. 603


Inlet Filtration Problems . .................................................................... 606
Evaporative Cooling ............................................................................ 607
Axial Flow Compressor ........................................................................ 607
Inlet Guide Vanes ................................................................................ 611
Compressor Blades . ............................................................................. 611
Diaphragms .......................................................................................... 611
Diaphragm Seals .................................................................................. 615
Diaphragm Contact ............................................................................. 615
Compressor Problems and Failures ..................................................... 615
Compressor Vanes and Blades ............................................................ 616
Cooling Air Contamination ................................................................. 631
Combustion Systems ............................................................................ 634
Diffusion-Type Combustors . ............................................................... 637
Dry Low-NOx Combustors . .................................................................. 641
Dynamic Combustion Monitors .......................................................... 648
Transition Piece . .................................................................................. 650
xiv • COGENERATION AND COMBINED CYCLE POWER PLANTS

Axial Flow Turbines ............................................................................. 653


Turbine Blades ..................................................................................... 662
Wheel Space . ....................................................................................... 671
Exhaust Manifold . ............................................................................... 672
Gas Turbine Expansion Joint Failures ................................................. 676
Heat Recovery Steam Generators ............................................................ 677
Failures Experienced in HRSGs ............................................................ 680
Chemical Sampling and Analysis ............................................................. 689
Man Service Platforms . ............................................................................ 690

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Freeze Protection ..................................................................................... 691
Steam Turbine .......................................................................................... 692
HP Turbine Section ................................................................................... 694
IP Turbine Section . ................................................................................... 699
LP Turbine Section .................................................................................... 702
Foreign Object Damage/Domestic Object Damage . .............................. 706
Gland Seal Systems ................................................................................... 708
Lubrication System Failures ..................................................................... 709
Bearings . .............................................................................................. 715
Gears ......................................................................................................... 722

APPENDIX A 725

APPENDIX B 729

BIBLIOGRAPHY 731

INDEX 747

ABOUT THE AUTHOR 761


PREFACE

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A Handbook for Cogeneration and Combined Cycle Power Plants discusses the
design, fabrication, installation, operation, and maintenance of combined cycle
power plants. The book has been written to provide an overall view for the
experienced engineer working in a specialized aspect of the subject and for the
young engineering graduate or undergraduate student who is being exposed to
the field of power plants for the first time. The book has proven to be very useful
as a textbook for undergraduate and graduate courses as well as for in-house
company training programs related to power generation, and I believe that the
new edition will further extend the knowledge of the engineer in this field.
The second edition is not only an updating of the technology, which has taken
great leaps forward since the year 2001, but I have also rewritten the introductory
chapter to bring the reader new information in the power industry, especially
carbon sequestration technology, which will be a topic of great interest in the
years to come. The power industry has, in the past 8 years, embraced the combined
cycle power plants and, with the new high-efficiency advanced gas turbines, is at
the center of this growth segment of the industry. This has led to the rewriting of
the following chapters: Chapter 1, “An Overview of Power Generation”; Chapter
5, “Steam Turbines”; Chapter 7, “Heat Recovery Steam Generators”; and Chapter
8, “Condensers and Cooling Towers.”
A new chapter has been introduced, Chapter 15, “Case Histories of Problems
Encountered in Cogeneration and Combined Cycle Power Plants.” This is an
extensive treatise on the many problems associated with the combined cycle
power plants and some of the solutions that have achieved higher efficiencies
and reliability. This chapter explains in depth the problems encountered and with
145 figures fully illustrates the many failures encountered in cogeneration and
combined cycle power plant applications.
This book has been used extensively by engineers in the industry, and I have
used it in the many courses I have taught in this area. The suggestions from these
engineers have guided me in my writing of the second edition of this book. The
new chapters have been written with an eye toward the new issues both from a
technical and legal point of view in the operating of power plants. In this new
edition, I have introduced extensive sections on the chemical treatment of the
water used in combined cycle power plants. The chemistry sections and related
information have been provided by David Addison of Thermal Chemistry Limited,
New Zealand. I have also used many topics that have been well researched by the
Electric Power Research Institute in its many publications.
xvi • COGENERATION AND COMBINED CYCLE POWER PLANTS

Cogeneration and combined cycle power plants are not new, but with major
improvements in all of the building blocks such as power plant, gas turbines,
HRSGs, steam turbines, and condensers, an update of the book was necessary.
Technology efficiencies in the mid-1950s are common today, and with a little bit
of ingenuity, efficiencies in the low 1960s will be possible. With emphasis on CO2
reduction, these high efficiencies will make it possible to achieve the lofty goals
of greenhouse gas reductions. These high efficiencies have totally revolutionized
the industry, making the old steam plants a thing of the past.
The use of cogeneration and combined cycle power plants in all industries,

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and in the power generation field, has mushroomed in the past few years. It is to
these users and manufacturers of cogeneration and combined cycle power plants
that this book is directed. The book, with its new chapter on case histories, will
give the manufacturer a glimpse of some of the major problems associated with
his equipment in the field and help the user to achieve maximum performance
efficiency and high availability for his plant.
I have been involved in the research, design, operation, and maintenance
of various types of combined cycle power plants since the early 1960s. I have
also taught courses at the graduate and undergraduate level at the University
of Oklahoma and Texas A&M University, and now, in general, to the industry
for the past 30 years. I have taught over a hundred courses to 3000 students
from over 400 corporations around the world. The enthusiasm of the students
associated with these courses gave me the inspiration to undertake this endeavor
of updating the book. The many courses I have taught over the past 37 years
have been an educational experience for me as well as for the engineers who
have participated in these courses. The Texas A&M University Turbomachinery
Symposium, which I had the privilege to found and chair for seven years and
which is now in its 38th year, is a great contributor to the operational and
maintenance sections of this book. The discussions and consultations that
resulted from my association with highly professional individuals have been a
major contribution to both my personal and professional life as well as to this
book.
In this book, I have tried to assimilate the subject matter of various papers,
and sometimes diverse views, into a comprehensive, unified treatment of
combined cycle power plants. Many illustrations, curves, and tables are
employed to broaden the understanding of the descriptive text. Mathematical
treatments have been deliberately held to a minimum so that the reader can
identify and resolve any problems before he is ready to execute a specific design.
In addition, the references direct the reader to sources of information that will
help him to further investigate and solve his specific problems. It is hoped that
this book will serve as a reference text after it has accomplished its primary
objective of introducing the reader to the broad subject of combined cycle power
plants.
I wish to thank the many engineers whose published work and discussions
have been a cornerstone to this work. Lastly, I wish to acknowledge and give
special thanks to my wife, Zarine, for her readiness to help and her constant
encouragement throughout this project. I also would like to thank my assistants
Donna Masters and Shannon Reynolds for the many hours they have spent in
helping me put this new edition together.
PREFACE • xvii

I sincerely hope that this new edition will be educational and interesting to
read as it was for me to write and that it will be a major reference in the fast-
growing field of cogeneration and combined cycle power plants.

MEHERWAN P. BOYCE
HOUSTON, TEXAS
September 2009

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