TERM PAPER

OF
Project management

Topic: - Power cogeneration plant

Submitted to:-
Mr. Jagjeet Singh

Submitted by:-

Jasneet kaur

RT1809A07
BBA (5th SEM)
Introduction to cogeneration plant
Cogeneration (also combined heat and power, CHP) is the use of a heat
engine or a power station to simultaneously generate both electricity and
useful heat.

All power plants must emit a certain amount of heat during electricity
generation. This can be into the natural environment through cooling
towers, flue gas, or by other means. By contrast CHP captures some or all of
the by-product heat for heating purposes, either very close to the plant, or—
especially in Scandinavia and eastern Europe—as hot water for district
heating with temperatures ranging from approximately 80 to 130 °C. This is
also called Combined Heat and Power District Heating or CHPDH. Small CHP
plants are an example of decentralized energy.

In the United States, Con Edison distributes 30 billion pounds of

350 °F/180 °C steam each year through its seven cogeneration plants to
100,000 buildings in Manhattan—the biggest steam district in the United
States. The peak delivery is 10 million pounds per hour (corresponding to
approx. 2.5 GW) This steam distribution system is the reason for the
steaming manholes often seen in "gritty" New York movies.

Other major cogeneration companies in the U.S. include Recycled Energy

Development and leading advocates include Tom Casten and Amory Lovins.

By-product heat at moderate temperatures (212-356°F/100-180°C) can also

be used in absorption chillers for cooling. A plant producing electricity, heat
and cold is sometimes called trigeneration or more
generally: polygeneration plant.

Cogeneration is a thermodynamically efficient use of fuel. In separate

production of electricity some energy must be rejected as waste heat, but in
cogeneration this thermal energy is put to good use.
Types of plants
Topping cycle plants primarily produce electricity from a steam turbine. The
exhausted steam is then condensed, and the low temperature heat
released from this condensation is utilized for e.g. district
heating or water desalination. Bottoming cycle plants produce high
temperature heat for industrial processes, then a waste heat recovery
boiler feeds an electrical plant. Bottoming cycle plants are only used when
the industrial process requires very high temperatures, such as furnaces
for glass and metal manufacturing, so they are less common.

Large cogeneration systems provide heating water and power for an industrial
site or an entire town. Common CHP plant types are:

 Gas turbine CHP plants using the waste heat in the flue gas of gas
turbines. The gaseous fuel used is typically natural gas
 Gas engine CHP plants (in the US "gaseous fuelled") use a reciprocating
gas engine which is generally more competitive than a gas turbine up to
about 5 MW. The gaseous fuel used is normally natural gas. These plants
are generally manufactured as fully packaged units that can be installed
within a plantroom or external plant compound with simple connections
to the site's gas supply and electrical distribution and heating systems.
Typical large example see
 Biofuel engine CHP plants use an adapted reciprocating gas engine
or diesel engine, depending upon which biofuel is being used, and are
otherwise very similar in design to a Gas engine CHP plant. The
advantage of using a biofuel is one of reduced hydrocarbon
fuel consumption and thus reduced carbon emissions. These plants are
generally manufactured as fully packaged units that can be installed
within a plantroom or external plant compound with simple connections
to the site's electrical distribution and heating systems. Another
variant is the wood gasifier CHP plant whereby a wood pellet or wood
chip biofuel is gasified in a zero oxygen high temperature environment;
the resulting gas is then used to power the gas engine. Typical smaller
size biogas plant see
 Combined cycle power plants adapted for CHP
 Steam turbine CHP plants that use the heating system as
the steam condenser for the steam turbine.
 Molten-carbonate fuel cells have a hot exhaust, very suitable for
heating.
  Nuclear Power

Smaller cogeneration units may use a reciprocating engine or Stirling engine.

The heat is removed from the exhaust and the radiator. These systems are
popular in small sizes because small gas and diesel engines are less expensive
than small gas- or oil-fired steam-electric plants.

Some cogeneration plants are fired by biomass , or industrial and municipal

waste (see incineration).

Heat Recovery Steam Generators

A Heat Recovery Steam Generator or HRSG is a steam boiler that uses hot
exhaust gases from the gas turbines or reciprocating engines in a CHP plant to
heat up water and generatesteam. This steam in turn drives a steam
turbine and/or is used in industrial processes that require heat.

HRSGs used in the CHP industry are distinguished from conventional steam
generators by the following main features:

 The HRSG is designed based upon the specific features of the gas
turbine or reciprocating engine that it will be coupled to.

 Since the exhaust gas temperature is relatively low, heat transmission

is accomplished mainly through convection.

 The exhaust gas velocity is limited by the need to keep head losses
down. Thus, the transmission coefficient is low, which calls for a large
heating surface area.

 Since the temperature difference between the hot gases and the fluid
to be heated (steam or water) is low, and with the heat transmission
coefficient being low as well, the evaporator and economizer are
designed with plate fin heat exchangers.
ABSTRACT:
Over the last few years the power production industry is facing rapid changes.
Due to the liberalization of the electricity market, power plants are facing
operational requirements that have not been anticipated during their design.
Plants being designed as base load plants are operating in load following and
even start/stop regimes. At the same time, also due to the liberalization,
electricity prices are under pressure and power plants receive lower operating
incomes. These effects result in a drive towards maximizing net power
production under operating loads not anticipated during the design of the
plants. Most of all the aim is to do so at minimum capital investment. In this
paper two cases are being described. One case describes the optimization of
the water cooled condenser system in a 540MW power plant. The other case
describes the optimization of the inlet air system of a 35MW gas turbine
based cogeneration plant.

COLD END OPTIMIZATION:

The impact of cooling water flow rate on power plant performance
insignificant. The optimum amount of cooling water depends primarily on
cooling water temperature and power demand. Adequate guideline son
operators how to operate and optimize the cooling water system are Valuable
tools to increase power plant revenues. The objective of the described work
was the development of such guidelines for a coal
Fired 540 MW power plants. Computer simulation using a detailed
thermodynamic model combined with an economic model was used to find the
optimum points for various operating conditions. The thermodynamic model
simulates plant operation on a component by component basis. The component
models accurately take into account component performance under varying
operating conditions. Particular attention was focused on modelling of the
steam turbine, condenser and cooling system operation. The temperature of
this cooling water varies from around 1°C in winter up to 25°C in summer. The
cooling water flow rate can be controlled by adjusting the blade angle of the
cooling water pumps. Doing so, the cooling water flow rate can be varied
between 10 m3/s and 20 m3/s. During plant operation the objective is to
operate at the optimum cooling water flow rate from an economic point of
view. This optimum, however, is dependent on a number of conditions such as
plant load and cooling water inlet temperature. So a tool for the operators has
been developed to assist them to operate at this optimum cooling water flow
rate. For this purpose a development program has been defined amongst
others comprising setting up detailed thermodynamic plant performance
model, using PC based software.

The steps involved in the development program are:

1. Setting up a PC based thermodynamic model of the power plant, accurately
taken into account changes of cooling water flow rate and temperature and
their impact on condenser performance, turbine exhausts losses, extraction
steam flows for feed water heating etc.
2. Defining an equation that described cooling water pump power
Consumption as a function of flow rate.
3. Deriving cooling water flow rate from the condenser mass/energy
balance.
4. Blending the results from step 1 and 2 in one set of equations,
describing the net heat rate at a given plant load as a function of cooling
water flow rate and temperature. This set of equations is being
used for the optimization module.
5. Validate the method described above.
6. Adding economic data and implementation of the optimization
module in the process computer.
Thermodynamic plant model of the optimization method:
Using the above model, plant performances can be calculated under
varying conditions, taking into account numerous parameters.
After validation of the model two ways of implementation have been
considered:
1. Implementation of the model in the process computer.
2. Derive polygons that describe plant performance as a function of selected
input parameters and implement the polygons in the process computer

By calculating performance for several combinations of cooling water flow and

cooling water temperature, a set of heat rate curves can be generated. Each
curve shows the change of net specific heat rate at constant cooling water
temperature, as a function of cooling water flow rate. It can be clearly
recognized that at each cooling water temperature an optimal heat rate can be
reached. It can also be seen that for different cooling water temperatures,
different optimal cooling water flow rate sexist. This is still at a constant
heat input to the steam turbine.
The cooling water flow from the optimum heat rate at a given plant load and
cooling water temperature can be found by the differentiation of the
representative polynom. This exercise has been done for the other cooling
water temperatures and power production levels as well. As a result optimal
cooling water flow rates are found for each power production level and cooling
water temperature. This optimal poi

By calculating performance for several combinations of cooling water flow and

cooling water temperature, a set of heat rate curves can be generated. Each
curve shows the change of net specific heat rate at constant cooling water
temperature, as a function of cooling water flow rate. It can be clearly
recognized that at each cooling water temperature an optimal heat rate can be
reached. It can also be seen that for different cooling water temperatures,
different optimal cooling water flow rate sexist. This is still at a constant
heat input to the steam turbine.
The cooling water flow from the optimum heat rate at a given plant load and
cooling water temperature can be found by the differentiation of the
representative polynom. This exercise has been done for the other cooling
water temperatures and power production levels as well. As a result optimal
cooling water flow rates are found for each power production level and cooling
water temperature. This optimal point
can also be connected with a curve. This curve shows the optimal cooling water
flow rate (mopt) at a certain power production and can be described as
2nddegree poloniums
In the polynominans of table 2 the coefficients a0, a1 and a2 are a
function of the power
production and can also be described by a polynomian.
Based on this equation a graph is generated that is being displayed on the
operator’s monitor. Because the control parameter, the operator uses, is the
pump blade angle the curve has been converted from optional flow rate to
optimal blade angle.

Monitor screen of process computer:

In order to set the optimal angle the operator only needs to bring the
“cross” cursor on the screen to the relevant power curve.

COST SAVINGS
As an example the cost savings have been quantified for the 500 MW
operating point. Savings have been calculated for a 24 hour period, using fuel
costs of 100Rs/GJ.Theresult of a number of calculations is shown in figure 4.
From this figure it can be read how much the savings at different cooling
water temperatures are, compared to the operation with maximum cooling
water flow rate (20 m3/s)
HOT END OPTIMIZATION:
The impact of inlet air temperature on gas turbine and thus gas turbine based
power plant performance is significant. This is usually summarized in one line:
the lower the air inlet temperature, the better is the plant performance. Only
a few people realize, however, that this relates to thermodynamic
performance(efficiency) only. High thermal efficiencies do not necessarily
mean good financial performances. This is especially the case for cogeneration
plants that by definition generate two products (power and heat) from one (or
more) fuels. The fact that a cogeneration plant delivers multiple products with
individual prices some of which change from hour to hour and the liberalization
of the electricity market has made model based optimization tools invaluable
when optimizing cogeneration plant performance financially. The 35 MW
industrial cogeneration plant in this example comprises a LM5000 aero
derivative gas turbine, a HRSG with supplementary firing producing HP steam.
The HP steams partly delivered at HP level to a HP steam consumer and partly
expanded in a
back pressure steam Turbine (see figure 5) to be delivered at LP level to
LPsteam consumers. Fuel used is natural gas. For this plant the natural gas
price is more or less constant over larger periods of time, but the electricity
price at night is only approx. 50% of the day price.
Thermodynamic plant model of 35MWcogeneration plant
In contrast to the 500MW coal fired plant described before, it was decided
for this industrial cogeneration plant to aim at a full on line plant monitoring
and optimization system (Efficiency Map TM. This system reads in plant data
from DCS, every 5-10 minutes. Data is then used to:
· Monitor plant performance (fouling etc.)
· Monitor measurement deviations
· Calculate optimum plant operation

GAS TURBINE PARTLOAD:

Over the last few years during the night time, the electricity export price has
dropped significantly to 1160Rs/MWhr, while gas price went up to approx.
203-220Rs/GJ. As a result, gas turbine full load operation is under these
conditions not profitable anymore. At full load the gas turbine generates too
much electricity of low value at the expenses of a large amount of expensive
natural gas. When analyzing this, it becomes obvious that part load operation
on the gas turbine is financially preferable, even at the cost of additional
supplementary firing on the HRSG. This supplementary firing is a necessity to
compensate for the reduced gas turbine exhaust heat in order to keep the
steam production at the required level. From figure 6 it can be read that
reducing gas turbine load to60% improves financial performance with an
amount of 4350Rs/hr.

OPTIMIZATION OF PARTLOAD PERFORMANCE

Using a Gate Cycle TM plant performance model, the effect of a number of
controllable parameters on financial plant performance has been studied. The
results are interesting. It turns out that increasing the gas turbine inlet
temperature has a positive effect on financial plant performance! From figure
6 it can be read that at60% gas turbine load, revenues can be increased with
another 85 EURO/hour, by increasing inlet air temperature. It is, however,
important to note that the source used for inlet air heating(hot water, steam,
etc.) has a significant impact on plant performance and should therefore be
taken into account. Therefore the plant performance model should be covering
the complete power plant cycle, not just the gas turbine. Contrary to the coal
fired power plant before, this industrial cogeneration plant has been equipped
with an on line power plant performance system. This allows the operator to
see on line what the effect of his actions on financial plant performance are.
The system uses current energy prices and calculates plant revenues,
continuously on line On this figure the effect can be seen for changing from
part load
operation (T44 ~700°C)to full load operation (T44 ~740°C).
As a result of the high fuel price and the low electricity price, the plant is
working with, the full load operation causes a reduction of revenues of NLG
50,-/hour.
Inlet air heating under the same conditions will then reduce electricity
production costs
by 116-232Rs/MWhr
CONCLUSION:
Plant performance models are an invaluable tool for financial power plant
optimization, in a changing, liberalizing energy market. This applies for all
kinds of plants ranging from industrial cogeneration plants to coal fired power
plant. They are set up by using software such as Gate Cycle TM are capable of
optimizing all kinds of controllable parameters of a power/ cogeneration plant.
In a power plant a change in the cooling water flow rate, cooling the condenser
of a power plant causes changes in condenser pressure and exhaust losses of
the steam turbine and has a significant impact on plant performance. A PC
based thermodynamic model has been used to quantify the effect on the plant
performance. Polygons derived from this model are built in the DCS of the
plant, showing operators the optimal cooling water flow, at varying conditions.
As a result significant financial performance gains are reached. In an
industrial cogeneration plant a change of gas turbine inlet air temperature has
a significant impact on plant performance. A PC based thermodynamic plant
model has been set up and built into an on line plant performance monitoring
system. Depending on energy prices and plant configuration significant
financial savings can be realized by increasing gas turbine inlet temperature