GAS-FIRED COMBINED-CYCLE POWER PLANTS HOW DO THEY WORK?

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Cover picture: Gas turbine compressor with combustion chamber
CONTENTS

At a glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05

1. How does a gas-fired combined-cycle power plant work? . . . . . . . . . . . . . . . . . 06

1.1 The gas-fired combined-cycle power plant – in model form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07

1.2 The gas turbine: the heart of the power plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08

1.3 The water/steam cycle: more than just hot air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09

1.4 The high-voltage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.5 The control station: control and security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2. What are the positive aspects of a gas-fired combined-cycle power plant? . . . . 12

2.1 The issue of efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.2 Cost matters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.3 Modern combustion technology: a plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3. EGL projects in Italy (inserts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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1 – Model of an EGL gas-fired combined-cycle power plant

AT A GLANCE

A gas-fired combined-cycle power plant, also known as a Combined Cycle Gas Tur-
bine Power Plant, combines the strengths of two thermal processes in ideal fashion:
electricity production using a gas turbine together with a steam turbine. The acronym
normally used to describe this system is CCGT.

Around two thirds of the electrical power generated is produced by the gas turbine.
In a similar way as an aeroplane engine, a mixture of compressed air and fuel is com-
busted. The hot gases that this process creates drive the turbine and, with it, the gene-
rator that is coupled to it.

The rest of the electrical power generated, roughly a third, is produced by the steam
turbine using the hot exhaust gases leaving the gas turbine. In the heat recovery steam
generator (HRSG) the exhaust gases transfer their heat to the circulating water: the
pressurised water vaporises, causing the temperature in the system to rise. The steam
drives the steam turbine and, with it, the generator that is coupled to it.

Gas-fired combined-cycle power plants are technologically advanced and used

throughout the world. Compared with other types of power plant, they are highly effi-
cient: the state-of-the-art EGL plants in Italy achieve a percentage in the region of 56,
meaning that the energy supplied in the form of fuel is converted into electricity as
efficiently as technically possible.

Investment costs are comparatively low because the main components are largely
standardised. The extremely powerful gas turbine allows for a compact power plant,
which minimises construction time to around two and a half years.

Gas-fired combined-cycle power plants are built modular, consisting of several

blocks. Each block is practically a self-contained power plant that can be operated inde-
pendently. The standardised EGL power plants all have two blocks with a combined yield
of around 760 megawatts. One of these power plants could cover about ten percent of
Switzerland’s annual energy needs.

With modern combustion engineering, the emission of harmful exhaust gases can
be controlled and minimised. Compared with all other conventional thermal plants, such
as coal-fired power plants, carbon dioxide and nitric oxide emissions are lowest when
plants are fired with natural gas.

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1. HOW DOES A GAS-FIRED COMBINED-CYCLE POWER PLANT WORK?

1 2

The gas-fired combined-cycle power plant combines two

thermal processes so well that the resulting electricity ge-
neration is as efficient as possible. Around two thirds of
the electricity is produced by the gas turbine, and the re-
maining third by the steam turbine coupled to it. Powered
by the expanding fuel gases (gas turbine) or the steam
(steam turbine), a mechanical rotation takes place in the
two turbines, which is then converted by the generators
into electrical energy.
The EGL power plants are designed as multi-shaft in-
stallations. This means that the two turbines are coupled
to separate generators. – This is in contrast to single-shaft
installations, where both turbines power the same genera-
tor. – The EGL power plants in Italy consist of two blocks
each, so they each have four drive machines (two gas and
two steam turbines) and four driven machines (genera-
tors).

1 – Gas turbine
2 – End winding of generator
1. HOW DOES A GAS-FIRED COMBINED-CYCLE POWER PLANT WORK?

1.1 The gas-fired combined-cycle power plant – in model form

high-voltage lines steam lines

4
medium and
low pressure steam turbine

6 generator

high pressure
steam turbine

5
condenser exhaust gas
stack

1
air intake

feed-water steam
pump

high-voltage lines
air intake

2
gas turbine

water

6 generator
gas supply combustion
heat recovery steam generator
compressor
chamber turbine
3

1. Ambient air is drawn in via filter stages and compressed in the compressor. 2. Gas turbine: air is compressed, na-
tural gas is mixed in. Combustion takes place, generating hot gases under high-pressure. The turbine powers the ge-
nerator and the compressor. 3. Heat recovery steam generator: water is vaporised using the hot exhaust gases from
the gas turbine. 4. Steam turbine: the steam powers the turbine. The resulting mechanical energy is transferred to the
generator. 5. Condenser: here the exhaust steam from the steam turbine is converted back into water by means of air
cooling. 6. Generators: here the mechanical energy from the turbines is converted into electricity.

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1. HOW DOES A GAS-FIRED COMBINED-CYCLE POWER PLANT WORK?

1 2

1.2 The gas turbine: the heart of the power plant

The gas turbine is the first stage in the process of produ-

cing electricity. The gas turbine compressor draws in air
from the environment via a filter (1. on the model). This
air is compressed in the compressor (2. on the model),
which means that it is elevated to a higher pressure, and
then directed into the combustion chamber. Fuel is fed
into this chamber in the form of natural gas, and combu-
stion takes place. This process produces hot gases that
are allowed to “relax” in the turbine, which means that
they are brought to virtually ambient pressure. The gas
spreads out and expands. The energy that this releases
is converted into a mechanical rotation just like a toy
balloon when air is escaping from it. Here too the pres-
sure compensation (expansion) brings about the motion,
the action of the balloon “darting off”. The mechanical
rotation powers the compressor and the generator. The
generator converts this energy into electricity.
When the hot gas exits the turbine as exhaust gas,
it has a temperature of around 600°C. This heat energy
is then transfered to the water in the heat recovery
steam generator. The second stage of electricity genera-
tion then takes place: the water/steam cycle where the
pressurised water is heated and vaporised.
We regard the gas turbine as the heart of the power
plant. Not only does it produce two thirds of the electri-
city, it also gives the power plant its name. Diesel oil

1 – Heat recovery steam generator

2 – Gas turbine compressor
1. HOW DOES A GAS-FIRED COMBINED-CYCLE POWER PLANT WORK?
could also possibly be used as fuel, but the EGL plants
in Italy have not been designed for this. Natural gas has
lower exhaust gas emissions compared to diesel oil. In
addition, the cost and effort needed to maintain and ser-
vice turbines powered with natural gas is usually lower. A
general overhaul, where heavily used parts have to be re-
placed, tends to be necessary only once every three ye-
ars. During such maintenance inspection times, it pays
for a power plant to have more than one block. One part
of the plant can carry on producing electricity normally
even if the other is undergoing inspection and is therefore
out of action for some time.
All EGL power plants use type V94.3A2 gas turbines.
They are manufactured by the Italian company Ansaldo,
under a licence provided by Siemens. The turbine weighs
roughly 300 tons and yields a nominal electrical output of
260 megawatts. By way of comparison, around 3,500 VW
Golfs together would be needed to produce this kind of
output.
1.3 The water/steam cycle: more than just hot air
A third of the total electrical output comes from the steam
turbine (4. on the model). The water/steam cycle uses
the heat energy of the exhaust gases that would other-
wise go to waste in the gas turbine process. This heat is
used to generate water vapour, which produces electricity
with the help of a steam turbine. The water/steam cycle
is closed, which means that it is always the same water
that is heated, vaporised and then converted back into
water in the condenser.
The heat recovery steam generator (3. on the model)
is a large and complex configuration consisting of bund-
les of pipes and drums. It has three areas, each with a
different pressure level: one high, one medium and one
low. By dividing into these three levels, it is possible to
harness an impressive amount of the energy contained in
the exhaust gas.
In all EGL power plants the boiler is roughly 45 metres
high and 17 metres wide.
The steam turbine (4. on the model), like the boiler, is
divided into three pressure levels: one high, one medium
and one low. The respective area of the steam boiler sup-
plies the steam turbine with the correct steam. This is
then allowed to “relax” in the turbine; in other words, it
releases pressure. The turbine converts the steam
energy into a mechanical rotation that is then transferred
to the generator. There, it is transformed into electricity.
The steam turbines for all EGL power plants in Italy are
manufactured by Ansaldo under a licence provided by
BBC (ABB).
The generator’s nominal output is 132 megawatts. If
you again compare this output with a VW Golf, you would
need another 1,800 vehicles to produce this level of
output.
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1. HOW DOES A GAS-FIRED COMBINED-CYCLE POWER PLANT WORK?

1 2

1 – Rotor of high pressure steam turbine

2 – Ventilators of condenser
1. HOW DOES A GAS-FIRED COMBINED-CYCLE POWER PLANT WORK?
The condenser (5. on the model), on account of its size,
is the most striking component of the power plant. The
steam exits the turbine under vacuum, i.e. negative pres-
sure. It flows through pipes a few metres in diameter into
the condenser, which is cooled by air. Large ventilators
add ambient air, which cools the steam right down until it
becomes water again: it is condensed. The feed-water
pump then returns this “condensate” to the boiler. And
the cycle starts afresh.
1.4 The high-voltage system
The alternating current generated in the plant cannot be
stored. Power plants therefore need an electrical system
that reliably conveys the electricity produced to consu-
mers. The power plant’s own transformers convert the
electricity produced so that it can be fed directly into the
high-voltage network. In the event of a disruption to the
high-voltage network, the plant automatically begins to
run down in a safe mode. As soon as the electricity grid
is available again, and the corresponding demand exists,
the power plant automatically connects to the grid again
and supplies the required output.
1.5 The control system: control and security
The control system in the plant’s central control room
steers, controls and monitors all the processes and ope-
rations in the power plant. It records all the major se-
quences and process variables, and assists human inter-
vention. It is also able to draw comparisons between
target and actual conditions by itself and to respond to
them. In addition, the continuous feedbacks sent by the
many sensors in the power plant trigger automatic re-
sponses.
Normally speaking, all standard operation sequences
within the power plant are fully automated from start to
finish. If necessary, operating staff can purposefully in-
tervene and make improvements.
The system collects and stores a large volume of ope-
rational data that is important for specific analyses.
The historical data record also makes it possible to de-
termine maintenance and inspection times precisely.
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2. WHAT ARE THE POSITIVE ASPECTS OF A GAS-FIRED COMBINED-CYCLE POWER PLANT?

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2.1 The issue of efficiency

A plant’s availability is the key to its cost efficiency: to

what extent is the power plant ready for operation (after
scheduled and unscheduled downtimes)? Gas-fired com-
bined-cycle power plants can achieve very high values up-
wards of 95 percent if maintained well. This means that
they are connected to the grid roughly 345 days of the
year on average.
Compared with other types of power plant, gas-fired
combined-cycle power plants boast a high level of effi-
ciency. They convert the energy introduced in the form of
natural gas into electricity with the least amount of loss
that is technically feasible. It is not possible to achieve
zero loss given that friction and heat transfer always
cause some energy to be lost. The gas turbine manages
a level of efficiency of around 35 percent. The water/
steam cycle coupled to it significantly raises the effi-
ciency for the entire plant by using the heat energy emit-
ted by the exhaust gases from the gas turbine to produce
steam and, therefore, to generate electricity.
This way, the EGL plants in Italy achieve excellent va-
lues of roughly 56 percent. Coal-fired power plants tend
to be 10 to 15 percentage points below this level. While
it is true that plant efficiency is slightly lower if cooling is
done with air, as opposed to cooling with water, this does
offer greater independence for plant operation and pro-
tects natural water resources.
But it is not just the features of the plant itself that are
key to its cost efficiency. Other decisive factors include
the location and the professionalism of plant operation.
An important consideration in the choice of location is

1 – Rotor of low pressure steam turbine

2 – Condenser
2. WHAT ARE THE POSITIVE ASPECTS OF A GAS-FIRED COMBINED-CYCLE POWER PLANT?
the proximity to a high-voltage power line (380 kilovolts).
Short distances mean that transmission losses can be li-
mited. In addition, it is important that line capacities to
consumer centres are adequate. Like connection to the
high-voltage network, connection to the natural gas supply
is also very important. Therefore, an ideal location for a
power plant is one that is close to the high-voltage network
and to the natural gas pipeline.
Well trained, experienced personnel are a basic requi-
rement for reliable operation of a power plant, and one on
which EGL places special emphasis. It recruits its staff
early and offers continuous training for their specialist du-
ties. The EGL employees responsible for operation on site
ensure the availability of the plant. The EGL specialists at
head office make decisions regarding the use of the
power plant and production volumes.
2.2 Cost matters
The investment costs for a gas-fired combined-cycle
power plant are lower than those for coal-fired power
plants and other conventional thermal plants, standing at
around 0.6 million euros per megawatt of installed capa-
city, whereas for coal-fired power plants, for example,
twice that amount can be expected. The reasons for this
are the largely standardised main components of this type
of power plant and the short construction time of just two
and a half years or so. Depending on the design of the
plant, it is even possible to go into operation with just the
gas turbine first and to complete the water/steam cycle
in parallel. That way, the investor can start generating in-
come from the sale of electricity earlier, thereby achieving
a better return. A gas-fired combined-cycle power plant
has a useful life of 25 to 30 years, which is comparable
with other types of power plant.
Production costs for electricity, measured in euros per
megawatt hour, depend very heavily on fuel costs. With
today’s natural gas prices (as at autumn 2006), their
share can account for up to 70 percent. This heavy depen-
dency suggests that it is better to use gas-fired combined-
cycle power plants as medium load electricity generating
plants: this means taking advantage of their flexibility and
only operating them when electricity market prices are at-
tractive.
The block size that has been chosen for all EGL power
plants (380 megawatts each), guarantees attractive eco-
nomies of scale, measured on production costs. Smaller
units require more specific investment expenditure and
therefore generate fewer profits.
2.3 Modern combustion technology: a plus
Gas-fired combined-cycle power plants emit greenhouse
gases. Compared with all other fossil-thermal plants, that
are all plants with combustion processes, the lowest
emissions of carbon dioxide and nitrogen oxide (NOx) are
from plants operated with natural gas. The values for
coal-fired power plants, for example, are roughly twice as
high. Natural gas is regarded as a relatively clean fuel.
Continuous monitoring of the combustion also helps to
control and minimise the emissions.
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Tel. +41 44 749 41 41
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