Plant Operations

Upon completion of this

section, you will be able to
perform the following:
Plant Operations
List the major steps of a combined cycle
plant startup
Define the following terms:
Spinning Reserve
Base Load
Peak Load
List the steps required to place the HRSG
in service
Identify the major concern during steam
turbine startup and operation
Plant Operations
Describe the primary purpose of a
combined cycle plant
List the three operating modes of a
combined cycle plant
List the steps required to safely shutdown
a combined cycle plant
Define the term Layup associated with the
HRSG and steam turbine
Answer the questions correctly at the end
of the Section
Plant Operations
Normal Startup
Prior to unit startup, all support systems,
power sources, and control devices must be
checked and aligned for operation. Typically,
these checks depend on individual station
operating procedures and requirements, but
may include such areas as correct valve
alignment, correct power supply breaker
positions, returning tagged out equipment to
service, aligning control systems.
Plant Operations
Combustion Turbine Startup
Combustion turbine generators are provided
with digital control systems which are
programmed to sequentially start the unit and
place it in service; generally at the push of a
button. The control system also starts and
stops base mounted and auxiliary equipment
which supplies cooling, lubrication, fuel and
protection for the combustion turbine and the
associated generator.
Plant Operations
Combustion Turbine Startup
Spinning Reserve
Pre-Selected Load
Base Load
Peak Load
Plant Operations
Combustion Turbine Startup
Spinning Reserve. In combined cycle
applications, Spinning Reserve is
typically selected as the load option when
starting the unit from cold conditions.
Automatic loading of the unit to the 2 to 10
megawatt spinning reserve setpoint
provides a positive non-fluctuating
electrical load on the generator without
exhausting excessive heat into the HRSG.
Plant Operations
HRSG Startup

The HRSG, located at the exhaust end of the

combustion turbine, efficiently utilizes the excess
thermal energy in the combustion turbine exhaust
gases to generate high pressure, superheated
steam. Because of its location, the HRSG is
automatically placed in operation in conjunction
with the combustion turbine.

Plant Operations
Preparing the HRSG for operation
consists of following evolutions:
Filling and venting the feedwater heater
Establishing deaerator water level and
steam pressure
Filling and venting the economizers
Establishing steam drum water level
Opening the superheater and reheater
vents and drains
Plant Operations
HRSG Startup
A simplified schematic of a single
pressure, reheat HRSG is
illustrated in Figure 16-1.
Plant Operations
A basic law of thermodynamics states that the
rate of heat transfer to cold is dependant upon
the temperature difference between the
objects. HRSGs are designed on the basis of
this thermodynamic principle. During base
load operation the temperature of the
combustion turbine exhaust gases decreases
as it progresses through the HRSG due to
heat transfer through the boiler tubes. By the
time the exhaust gas reaches the feedwater
heater, the exhaust gas temperature has been
reduced to less than 300F.
Plant Operations
As per design calculations, the
feedwater heater is sized with the
appropriate heat transfer surface to
obtain a specific water outlet
temperature when the unit is
operating at base load. As illustrated
in Figure 16-1; the pre-heated
water is routed to the deaerator.
Plant Operations
Steam Generation
Steam from the HRSG superheater
is supplied to the steam header for
use by the steam supply systems
and the steam turbine.
Plant Operations
HRSG Drum Level Control
Maintaining proper steam drum level
is a critical function and can not be
overstressed. An excessively high
drum level will flood the moisture
separators located within the steam
drum, resulting in moisture carry over
to the superheater and a steam turbine
trip.
Plant Operations
Steam Turbine Startup
Steam Turbine Pre-warming
One of the primary concerns of
steam turbine operation is the
gradual and uniform heating and
cooling of the rotors, shells, and
valves.
Plant Operations
Steam Turbine Startup
During steam turbine pre-warming
and startup, the operator must be
aware of the following limitations:
Thermal stress and distortion
Vibration
Rotor and shell differential
expansion.
Plant Operations
Steam Turbine Startup
Maintaining Steam Temperature
and Pressure
During the steam turbine warm-up
process, the steam seals can be
placed in service followed by the
application of the condenser
vacuum system.
Plant Operations
Steam Turbine Startup
Fast Starts
As previously discussed in Section
16.1.1, Normal Startup, there are
specific points of a combined cycle
plant startup where proper warm-
up of components must take place;
i.e. the HRSG and steam turbine.
Plant Operations
Fast Starts
When determining loading rates, each
combustion turbine manufacturer takes
the following parameters into
consideration:
Vital clearances between rotating parts
Thermal fatigue of metal parts
The rate of differential expansion; not only
between parts of different materials, but
between parts of different thickness.
Plant Operations
Operating Modes

Base Load
Manufacturers publish the rated
output of their combustion turbine
generator sets based on industrial
standard operating (ISO) conditions.
Plant Operations
Operating Modes
This baseline data is established
during steady state operation after
each of the following conditions:
Initial startup of unit
Before and after a planned shutdown
Before and after scheduled
maintenance
Plant Operations
Operating Modes
Cycling Duty Cycling duty refers to
gradual, yet significant changes, either
increases or decreases, in unit output.
In combined cycle applications, the
electrical output from both the
combustion and steam turbine
generators can be simultaneously
changed to a target value.
Plant Operations
Peak Loading
Manufacturers design combustion turbines
with more than ample margins for thermal and
dynamic stresses on the combustion section,
turbine section, generator ventilation,
equipment coolers, etc. As a result, each unit
is designed somewhat better than is strictly
necessary. This margin of capability is done in
an effort to ensure reliability of the turbines as
well as long life and trouble-free operation.
Plant Operations
Normal Shutdown
Similar to a startup, the combustion turbine
control system decreases generator load at
a programmed rate during the shutdown
sequence. The rate of load reduction is
typically the same as the programmed
loading rate, i.e. 3 to 10 megawatts per
minute. As combustion turbine load
decreases, HRSG steam production
decreases proportionately.
Plant Operations
Emergency Shutdown
Emergency shutdowns are the least
desirable method of shutting down
any power plant. An EMERGENCY
STOP or TRIP pushbutton is
generally provided to simultaneously
trip both the combustion turbine and
steam turbine.
Plant Operations
Layup
When not required for operation,
the plant equipment must be
maintained in a layup condition to
preserve its integrity and to
prevent internal deterioration and
contamination of the piping and
components.
Plant Operations
Combustion Turbine
A short term layup maintains the
combustion turbine and auxiliary
systems in a state of readiness. During
a short term layup the combustion
turbine should be left on turning gear
to prevent rotor shaft bow and the
settling of the rotor onto the bearings.
Plant Operations
Heat Recovery Steam Generator
Unless boilers are stored properly,
they can corrode rapidly,
depending on the condition of the
metal surfaces. The type of lay up
required is determined by the time
period the HRSG is expected to be
out of service.
Plant Operations
If the HRSG is expected to be out of
service for several days and will be
required to return to immediate service,
a wet lay up should be performed. If the
HRSG is expected to be out of service
for longer than one week, and will not
be required for immediate readiness for
return on short notice, the boiler should
be placed into dry storage.
Plant Operations
Steam Turbine
When the steam turbine is to be taken out
of service for a short time period, it is
essential that the steam turbine be left on
turning gear. The turning gear minimizes
temporary thermal bowing of the rotor. This
is more important when the unit is
restarted after a short time. Due to the
slow cooling rate of the casing and rotor,
the oil pump and coolers should remain in
service when the unit is on turning gear.
Plant Operations
Steam Turbine
When the steam turbine is to be taken out
of service for a short time period, it is
essential that the steam turbine be left on
turning gear. The turning gear minimizes
temporary thermal bowing of the rotor. This
is more important when the unit is
restarted after a short time. Due to the
slow cooling rate of the casing and rotor,
the oil pump and coolers should remain in
service when the unit is on turning gear.