UNIVERSIDAD PERUANA DE CIENCIAS APLICADAS

FACULTY OF ENGINEERING
INDUSTRIAL ENGINEERING

TECHNOLOGY AND INDUSTRIAL AUTOMATION

“FINAL WORK”

TITLE: “COMPRESSOR UNIT AND GAS TURBINE”

MEMBERS
Hurtado Laguna Jorge Alexander

Reyes Gomez Daryl Esther

Vasquez Tamayo Walter Adrián

COURSE CODE: IN196

SECTION: IN3

2018-1

1
ABSTRACT

In this work we will see how the importance of the compressor and gas turbine is described, for

this not only its efficient performance will be explained, but also the internal diagrams necessary

for the elaboration and operation of one. For which, we carry out a diverse investigation that

supports the case study.

On the other hand, we have to not only explain the theoretical framework of the work, but we

will also delve into the importance of the use of this machinery.

RESUMEN

En este trabajo veremos cómo se describe la importancia del compresor y la turbina de gas, para

esto no solo se explicará su rendimiento eficiente, sino también los diagramas internos necesarios

para la elaboración y operación de uno. Para lo cual, llevamos a cabo una investigación diversa

que respalda el estudio de caso.

Por otro lado, no solo debemos explicar el marco teórico del trabajo, sino que también

profundizaremos en la importancia del uso de esta maquinaria.

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TABLE OF CONTENTS

Introduction .............................................................................................................................. 4
Chapter 1: ................................................................................................................................ 7
Theoretical Foundation ............................................................................................................................................... 7
Objectives ................................................................................................................................................................. 12
Legal Framework ...................................................................................................................................................... 12

Chapter 2: .............................................................................................................................. 13
Process descriptions .............................................................................................................. 13
Block diagram ........................................................................................................................................................... 14
Flowchart .................................................................................................................................................................. 15

Chapter 3: .............................................................................................................................. 17
Control loops, pipe diagrams and instruments (P&ID) .............................................................................................. 17

Chapter 4: .............................................................................................................................. 19
Instrumentation (sensors, conditioners, controllers, drives and actuators) ................................................................ 19

Chapter 5 ............................................................................................................................... 22
Capital and operating costs ....................................................................................................................................... 22

References ............................................................................................................................ 24

TABLE OF FIGURES

Figure 1: Combined Cycle Power Plant .................................................................................... 5

Figure 2: Basic Diagram of the Combined Cycle ...................................................................... 8
Figure 3: Internal Combustion Turbine ..................................................................................... 8
Figure 4: Gas Turbine ............................................................................................................ 10
Figure 5: Structural Transverse Section Of Gas Turbine ........................................................ 14
Figure 6: Block Flow Diagram (BFD) ...................................................................................... 14
Figure 7: Process Flow Diagram (PFD) .................................................................................. 15
Figure 8: Pipes and Instruments Diagram (DT & I) ................................................................. 17

3
Introduction

A combined cycle power plant is a power plant in which the thermal energy of the fuel is

transformed into electricity by two thermodynamic cycles: the one corresponding to a gas turbine

(Brayton cycle) and the conventional water / steam turbine (Rankine cycle).

The gas turbine consists of an air compressor, a combustion chamber and the expansion chamber.

The compressor compresses the air at high pressure to mix it later in the combustion chamber

with the gas. In this chamber the combustion of the fuel takes place under conditions of

temperature and pressure that allow improving the performance of the process, with the lowest

possible environmental impact.

Then, the combustion gases are led to the gas turbine (2) for expansion. The energy is

transformed, through the blades, into mechanical energy of rotation that is transmitted to its axis.

Part of this power is consumed in dragging the compressor (approximately two thirds) and the

rest moves the electric generator (4), which is coupled to the gas turbine for the production of

electricity. The performance of the turbine increases with the inlet temperature of the gases,

which reach about 1,300 ° C, and which leave the last stage of expansion in the turbine at about

600 ° C. Therefore, to take advantage of the energy they still have, they are taken to the recovery

boiler (7) for use.

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 Figure 1: Combined Cycle Power Plant

COMBINED CYCLE POWER PLANT

1: Air Entrance
2: Gas Turbine
3: Combustion Chamber
4: Generator
5: Transformes
6: Electric Power
Transport Lines
7: Steam Boiler
8: Steam Turbine
9: Steam Turbine
Generator
10: Condenser
11: Cooling Towers

Source: UNESA (2014)

The steam boiler has the same components as a conventional boiler (preheater, economizer, etc.),

and, in it, the exhaust gases of the gas turbine transfer their energy to a fluid, which in this case is

water, that circulates inside the tubes for transformation into water vapor. From this moment on, a

conventional steam / water cycle is passed. Accordingly, this steam is expanded in a steam turbine

(8) that drives, through its axis, the rotor of an electric generator (9) which, in turn, transforms the

rotary mechanical energy into medium voltage electricity and High intensity. In order to reduce

transport losses, as occurs with the electricity produced in the generator of the gas turbine, its

voltage is increased in the transformers (5), to be taken to the general network by means of the

transport lines (6).

The steam coming out of the turbine passes to the condenser (10) for liquefaction by means of cold

water coming from a river or from the sea. The cooling water is subsequently returned to its source,

river or sea (open cycle), or is passed through cooling towers (11) for cooling, in the case of a

closed cycle system. The current development of this technology tends to couple the gas and steam

turbines to the same axis, thus activating the same electric generator together. (Elèctrica, 2018)

Table 1: Elements of the Combined Cycle

Elements of the Combined Cycle

1 Air Entrance
2 Gas Turbine
3 Combustion Chamber
4 Generator
5 Transformes
6 Electric Power Transport Lines
7 Steam Boiler
8 Steam Turbine
9 Steam Turbine Generator
10 Condenser
11 Cooling Towers
Source: Own Ellaboration

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Chapter 1:

Theoretical Foundation

1. - Operation of the combined cycle in thermal power plants:

The process of power generation through the combined cycle is based on the use of a gas turbine,

a steam turbine and a steam boiler.

The thermal cycle of the water-steam circuit begins with the aspiration of air from the outside,

which is conducted to the compressor of the gas turbine through some filters. Subsequently, the

air is compressed and combined with the fuel in a chamber where the combustion takes place,

producing a flow of hot gases that, when expanded, turn the gas turbine. Through the generator

coupled to the common axis this work is converted into electrical energy.

The gases that leave the gas turbine pass to the heat recovery boiler. In this the heat of the gases

is extracted producing water vapor under pressure for the steam turbine. To finally return the

gases to the atmosphere.

The steam that leaves the steam turbine passes through a condenser where it is transformed into

water. Subsequently the water produced by the condenser is pumped at high pressure to the

recovery boiler to start the cycle again. (ABB, 2014)

The following diagram shows the basic diagram of the combined cycle:

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 Figure 2: Basic Diagram of the Combined Cycle

Source: ABB (2015)

2.- Gas turbine

The gas turbine constitutes the core of the combined cycle power plant. It is an internal

combustion turbine that uses natural gas as the main fuel. Gas turbines are available in sizes

ranging from approximately one to more than 300 megawatts (MW) and are used to meet diverse

power needs, including propulsion (aircraft, ships, and trains), direct drive (pumps and

compressors) and stationary electricity generation.

For electricity generation, gas turbines are available in a wide range of capacities and

configurations, ranging from relatively small microturbines to very large turbines used for central

station power generation.

Figure 3: Internal Combustion Turbine

Source: ABB (2015)

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 Table 2: Elements of a gas turbine

Elements of a Gas Turbine

1 Generator
2 Compressor
3 AP turbine
4 BP turbine
5 Air Entrance
6 Burners
7 Output of combustion gases
Source: Own Ellaboration

The combustion takes place in two burner rings, so that the combustion products of the first

constitute the combustion air of the second. This technique, known as sequential combustion,

allows minimizing the emission of polluting products.

The operating mode of the gas turbine is based on the principle of the Brayton cycle. In which the

compressed air is mixed with the fuel and combustion occurs under conditions of constant pressure.

The hot gases, produced by the combustion, expand through a turbine, causing the movement of

the same and the consequent generation of energy. Of the energy generated, approximately 2/3 is

used to compress the air and 1/3 is available to produce electrical energy. (ABB, 2014)

A simple gas turbine consists of three main sections:

1. - Compressor: The compressor consists of 22 stages and is of axial type. It consists

of a series of fixed and mobile valves through which air is compressed from atmospheric

pressure (0.98 bars) to the optimum pressure for combustion (2 bars). Compressed air is

mainly used as combustion in combustion and a very small part is used to cool some parts

of the high pressure turbine of the gas turbine.

2. - Combustion chamber: In this area the fuel is mixed with the compressed air and

combustion takes place. Inside the combustion chamber we find the burners, arranged in

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two rings of 24 burners each. The design and arrangement of the burners is of vital

importance to have a good combustion and minimize emissions.

3. - Turbine: The turbine consists of different stages of fixed and mobile valves through

which the gases generated in combustion expand and cause the rotation of the motor

shaft. (ABB, 2014)

Figure 4: Gas Turbine

Source: ABB (2015)

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Table () provides a summary of gas turbine attributes.

Summary of Gas Turbine Attributes

Size Range Simple cycle turbines are available in sizes from
30 kW (known as microturbines) up to 300 MW
(there are a few products that exceed 300 MW)
Thermal Output Gas turbines produce high temperature exhaust,
and thermal energy can be recovered from this
exhaust to produce steam, hot water, or chilled
water (with an absorption chiller). The exhaust can
also be used directly for industrial process drying
or heating.
Part-load The electrical generation efficiency of gas turbines
Operation declines significantly as the load is decreased.
Therefore, gas turbines provide the best economic
performance in base load applications where the
system operates at, or near, full load.
Fuel Gas turbines can be operated with a wide range of
gas and liquid fuels. Natural gas is the most
common fuel.
Realibility Gas turbines are a mature technology with high
reliability.
Other Gas turbines have relatively low emissions and
require no cooling. Gas turbines have relatively
low installed costs.

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Objectives

 Achieve an effective diagram of the internal composition and electronic relations of a

Compressor and Gas Turbine.

 Sustain the effectiveness and use of a Compressor and Gas Turbine.

Legal Framework

In Peru there are the following two technical standards that regulate the use of gases in pipes

and machinery, which are:

• NTP111-010 Peruvian Technical Standard on Gas Installations

This Peruvian Technical Standard establishes the requirements that must be met by the piping

system for the supply of dry natural gas in the internal industrial facilities in reference to the

specification of the materials, the design and sizing, the construction and the minimum safety

requirements for a reliable operation. This Peruvian Technical Standard includes general

considerations and international normative references for pressure and measurement regulation

equipment, as well as safety requirements for the combustion systems of consumer equipment.

• NTP 111.021- 2006 Gas by Pipes

This Peruvian Technical Standard establishes the requirements that the pipe system in buried

polyethylene (PE) must fulfill for the supply of dry natural gas, referring to the design,

construction, pressure tests, commissioning and requirements for its maintenance.

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Chapter 2:

Process descriptions

The operation in a gas turbine has the following scheme: the air enters the compressor, in which

its pressure and temperature increase. Then, it is mixed with the fuel and the combustion process

occurs.

The hot gases expand to atmospheric pressure and produce work in the turbine.

The compressor operates with a part of the energy developed by the turbine (approximately 65%),

and the remaining energy is the mechanical energy available in the shaft of the turbine. An

electric generator is connected to the shaft of the turbine and produces electricity. The heat of the

combustion gases is recovered by heat recovery boilers, HRSG. The combustion is carried out

with a high excess of air, so that the exhaust gases at the outlet of the combustion chamber, with

a high temperature, have high concentrations of oxygen (up to 16%). The high temperature of

the cycle is recorded at this point (the output of the combustion chamber), the higher the

temperature, the higher the cycle efficiency, and with the technology available up to now,

temperatures of up to 1300ºC can be achieved. Later, after expanding, the exhaust gases leave

the turbine at a temperature between 450 and 600 ºC.

The operating characteristics of the gas turbines depend on the ambient air conditions, the quality

of the fuel, the supply of cooling water, the injection of water and the altitude mainly.

(INDIAMART, 2013)

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 Figure 5: Structural Transverse Section Of Gas Turbine

Source: Sahani (2013)

Block diagram

Figure 6: Block Flow Diagram (BFD)

Source: Ecured (2012)

Inputs: Air, Fuel, Gas Producer

Machines: Compressor, Combustor, Power Turbine, Generator

Outputs: Exhaust, Mecanical Power and Electricity

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Atmospheric air is drawn through the intake of the compressor from where compressed air is sent

to the combustion chamber (in red in the figure) in which the fuel enters with a constant flow rate

and is kept in continuous flame (The arrows in the drawing indicate the direction of flow). The

initial ignition is usually obtained by means of a spark (Start-up device). The air, heated in the

combustion chamber or combustor, expands through fixed nozzles or vanes and acquires a high

speed. Part of the kinetic energy of the air stream is transferred to the blades or buckets of the

turbine. A fraction of this energy is used to drive the compressor and the rest to produce work. In

the operation of the gas turbines there are several limitations of practical nature, which determine

a large part of the performance of this class of machines. Among these limitations, mention should

be made of the temperature and speed of the blades, the performance of the compressor, the

performance of the turbine and the heat transfer (in cycles with regeneration). (Ecured, 2012)

Flowchart

Figure 7: Process Flow Diagram (PFD)

Source: Edutec (2010)

The main components of the Gas Turbine Power Plant are:

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 Compressor: The compressor used in the plant is generally of rotatory type. The air at

atmospheric pressure is drawn by the compressor via the filter which removes the dust from

the air. The rotatory blades of the compressor push the air between stationary blades to raise

its pressure. Thus air at high pressure is available at the output of the compressor.

 Generator: A regenerator is a device which recovers heat from the exhaust gases of the

turbine. The exhaust is passed through the regenerator before wasting to the atmosphere. A

regenerator consists of a nest of tubes contained in a shell. The compressed air from the

compressor passes through the tubes on its way to the combustion chamber. In this way,

compressed air is heated by the hot exhaust gases.

 Turbine: The products of combustion consisting of a mixture of gases at high temperature

and pressure are passed to the gas turbine. These gases in passing over the turbine blades

expand and thus do the mechanical work. The temperature of the exhaust gases from the

turbine is about 900F.

 Start / Post Combustor: The air at high pressure from the compressor is led to the combustion

chamber via the regenerator. In the combustion chamber, heat is added to the air by burning

oil.The oil is injected through the burner into the chamber at high pressure to ensure

atomisation of oil and its thorough mixing with air.

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 Chapter 3:

Control loops, pipe diagrams and instruments (P&ID)

Figure 8: Pipes and Instruments Diagram (DT & I)

Source: ResearhGate (2014)

The Pipes and Instrumentation Diagram (P & ID) represents the equipment and flows of the

process, as well as the control instruments necessary for the operation of the gas turbine.

Table 3: Equipment in the Pipes and Instruments Diagram

Equipment
1. Steam
2. Turbine
3. Compressor
Source: Own Ellaboration

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 Table 4: Process Flows in the Pipes and Instruments Diagram

Process Flows
Internal link of the system (software or data)
Supply of instruments or connection to the process
Undefined signal
Source: Own Ellaboration

Table 5: Control instruments in the Pipes and Instruments Diagram

Control
instruments
1 Extraction Controller
2 Valve Manager
3 Governor
4 T&T T & T Valve
5 V1 Pneumatic Control Calve
6 V2 Pneumatic Control Calve
7 RCV Regulator Control Valve
8 Fs Flow Sensors
9 Ps Pressure Sensors
10 Pd Pressure Difference
11 Surge Controller
12 Capacity Controller

Source: Own Ellaboration

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 Chapter 4:

Instrumentation (sensors, conditioners, controllers, drives and actuators)

Sensors:

1. Remote Sensors: These pressure sensors have either a portable or permanent

configuration. Portable systems consist of pressure sensors that are connected to sensing

lines running to some or all of the combustors. Similar to the portable systems, permanent

systems provide sensors mounted outside the turbine enclosure.

2. Close Coupled Sensors: Close coupled sensors permanently mounted to a gas turbine are

ideal for monitoring combustion dynamics (instability). Operating at a wider frequency

range than remote sensors, the high sensitivity and higher temperature capability of these

sensors allow for precision measurement in turbine locations where the application of other

instrumentation is not possible.

3. On-Turbine Instability Sensors (OTIS): High temperature sensors directly mounted to

the combustor basket provide 24/7, consistent, reliable combustion dynamics data

monitoring so that tuning changes can be made at any time. On-Turbine Instability Sensors

allow for diagnostics, part fatigue analysis and the ability to continuously monitor and

control emissions. In addition, these sensors provide an output that can easily connect to

legacy combustion dynamics monitoring systems. By having sensors directly mounted to

the combustor, operators save time during combustion analysis. (SENSORS, 2018)

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Actuators

1. Fuel Control Valve: The use of electric actuated fuel control valves on gas turbines can

replace pressure regulator/gas loaders, throttle valves, and associated electrohydraulic

actuators. The roller screw, which consists of multiple threaded helical rollers assembled

in a planetary arrangement around a threaded shaft, is capable of carrying heavy loads for

thousands of hours even in very arduous conditions. This, combined with high torque servo

motor technology, provides a compact and powerful linear actuator solution for fuel valves.

2. Inlet Guide Vanes: For gas turbines with variable guide vanes, Exlar actuators provide

superior performance to other technologies. Precise positioning and feedback provides the

ability to fine-tune injector airflow to maintain CO and NOx emissions.

3. Bleed Valve: High accuracy and speed make Exlar servo electric actuators are an excellent

choice for your variable air bleed valves and inlet bleed heat valves.

4. Fuel Metering Valve: For gas metering utilizing ball valves, Exlar electric servo rotary

actuators provide high accuracy positioning. Directly coupled to the shaft, all linear

linkages are eliminated. (EXLAR, 2007)

Controllers

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1. Control Valve Servomotor:

It receives signal from intermediate pilot valve & actuate HPT & IPT control valves.

2. Turbine Shut Down Switch:

To trip turbine manually (locally) or from Unit Control Board (UCB).

3. Differentiator:

It prevents undue speed rise in case of more than 50% load throw off which causes anticipatory

closure of control valve of HPT and IPT.

Drives:

1. Electro Hydraulic Transducer:

It converts electric signal of 2 seconds diverted from generator circuit breaker (when opens)

into hydraulic signal & momentarily closes the control valve for 2 seconds to avoid over

speeding of turbine

2. Initial Steam Pressure Unloading Gear:

When main steam pressure falls below (90±2)% of rated value it throttles the control valve &

when main steam pressure falls below 70% of rated completely closes the control valve.

3. Turbine Shut Down Switch:

To trip turbine manually (locally) or from Unit Control Board (UCB).

Conditioners

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 1. Emergency Governor:

It consist of two centrifugal strikers which operates and trip the turbine in case of 11-12% of

over speed by closing ESV, IV, HPT & IPT control valves.

13. Emergency Governor Pilot Valve:

It receives emergency signal from emergency governor which operates turbine shut down

switch to trip turbine.

3. Load Limiter:

To limit the load rising beyond set point by limiting the opening of control valve by speed

governor. It trips the turbine at 14 to 15% over speed if emergency governor fails to operate.

Chapter 5

Capital and operating costs

Installed capital costs vary significantly depending on the scope of the plant equipment,

geographical area, competitive market conditions, emissions control requirements, and

prevailing labor rates. Gas turbine maintenance costs can vary significantly depending on; the

quality and diligence of the preventative maintenance program and operating conditions.

Typically, routine inspections are required every 4,000 hours to ensure that the turbine is free of

excessive vibration due to worn bearings and rotors or damaged blade tips. Routine maintenance

practices include running maintenance, predictive maintenance, performance testing, vibration

analysis, and preventive maintenance procedures. (ENERGY, 2016)

Table (6) shows estimated capital costs for six representative gas turbine systems.

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 Gas Turbine Capital and O&M Costs

Description 1 2 3 4 5 6
Net Electric Power (kW) 3304 4324 7487 10669 20440 40485
Combustion Turbine ($/kW) $908.0 $860.0 $683.0 $619.0 $563.0 $477.0
Emissions Control ($/kW) $28.0 $174.0 $126.0 $92.0 $74.0 $65.0
Balance of Plant ($/kW) $899.0 $712.0 $455.0 $389.0 $276.0 $231.0
Construction and Installation $1,305.0 $1,072.0 $753.0 $698.0 $562.0 $503.0
($/kW)
Total Installed Cost ($/kW) $3,320.0 $2,817.0 $2,017.0 $178.0 $1,474.0 $1,276.0
Total O&M (c/ /kWh) 1.3 1.3 1.2 1.2 0.9 0.9
Note: Costs are not intended to represent a specific product.

Table 6: Gas Turbine Capital and O&M Costs

Table (7) shows estimated prices for five types of gas turbine.

Gas Turbine Prices

Manufactured
Details Price KW HZ Fuel RPM
By

LM2500PE $16’100,000 47,600 60 Dual fuel General Electric 3,600

LM2500PE, Number 2
$6’850,000 22,600 60 General Electric
model MDW Diesel

Frame 6B /
$6’180,000 31,640 60 Diesel GEC-ALSTOM 3,600
PG654 15B

Frame 6B / Number 2
$5’620,000 123,520 60 Alstom
PG6531 Diesel

Frame 6B / Number 2
$5’420,000 92,970 60 HITACHI 3,600
PG6531 Diesel

Table 7: Gas Turbine Prices

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 References

ABB. (2014). Retrieved from

http://www.abb.com.pe/cawp/seitp202/bad82308e64184ad652578cd0042d39d.aspx

Ecured. (2012). Retrieved from https://www.ecured.cu/Turbina_de_gas

Elèctrica, A. E. (2018, Mayo). UNESA. Retrieved from http://www.unesa.es/sector-

electrico/funcionamiento-de-las-centrales-electricas/1343- central-ciclo-combinado

ENERGY, U. D. (2016, Julio). Advanced Manufacturing System. Retrieved from

https://www.energy.gov/sites/prod/files/2016/09/f33/CHP-Gas%20Turbine.pdf

EXLAR. (2007). Gas Turbine Electric Valve Actuators. Retrieved from

https://stevenengineering.com/Tech_Support/PDFs/EXLAR_GAS-TURBINE.pdf

INDIAMART. (2013). Retrieved from https://www.indiamart.com/sahani-trading-corporation/gas-

turbines.html

SENSORS, I. (2018). Combustion Dynamics Instrumentation . Retrieved from

http://www.pcb.com/Contentstore/mktgcontent/IMI_Downloads/IMI-App-
Combustion_LowRes.pdf

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