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Use of Chillers to Improve
Gas Turbine/Combined Cycle Plant Performance
Chillers are an effective method of cooling the gas turbine inlet
air – allowing for greater mass flow, and improved overall
power plant performance.
Chillers differ from evaporative coolers and foggers in that
chillers can reduce the dry bulb temperature to well below
the wet bulb temperatures.
We will evaluate the impact of two different types of chillers –
• Mechanical, and
• Absorption
We will use a General Electric 7241FA gas turbine with a
reheat steam cycle and a mechanical draft cooling tower.
Site conditions are –
• 80°F
• 50 % RH
• Sea level
• Natural gas fuel
To start, we will look at the basic combined cycle power plant
with no chillers installed. This will provide a reference cost
and performance basis.
80
50
35
8
25
Chiller Comparison
Summary
Chiller - Base Case Electric Chiller Steam Chiller
Project Cost Summary Reference Cost Reference Cost Reference Cost
I Specialized Equipment 71,384,700 73,589,300 2,204,600 73,620,300 2,235,600
II Other Equipment 3,871,109 4,543,770 672,662 4,267,599 396,491
III Civil 3,400,474 3,557,428 156,954 3,565,157 164,683
IV Mechanical 8,107,244 9,458,009 1,350,765 9,647,106 1,539,862
V Electrical 551,292 660,034 108,742 632,789 81,497
VI Buildings & Structures 2,998,989 3,080,381 81,392 3,047,653 48,664
VII Engineering & Plant Startup 6,112,089 6,326,665 214,576 6,399,382 287,293
Subtotal - Contractor's Internal Cost 96,425,897 101,215,588 4,789,691 101,179,987 4,754,090
VIII Contractor's Soft & Miscellaneous Costs 12,289,815 12,984,060 694,245 13,010,057 720,242
Contractor's Price 108,715,713 114,199,647 5,483,934 114,190,044 5,474,331
IX Owner's Soft & Miscellaneous Costs 9,784,414 10,277,968 493,554 10,277,104 492,690
Total - Owner's Cost 118,500,127 124,477,616 5,977,489 124,467,148 5,967,021
Gas Turbine Output - kW 157,185 176,293 19,108 176,293 19,108
Steam Turbine Output - kW 91,124 94,180 3,056 90,766 -358
Net Plant Output - kW 242,306 260,834 18,528 260,312 18,006
Net Plant Heat Rate - BTU/ kWH - (LHV) 6,261 6,360 99 6,373 112
Chiller Comparison
Summary
Chiller - Base Case Electric Chiller Steam Chiller
Project Cost Summary Reference Cost Reference Cost Reference Cost
I Specialized Equipment 71,384,700 73,589,300 2,204,600 73,620,300 2,235,600
II Other Equipment 3,871,109 4,543,770 672,662 4,267,599 396,491
III Civil 3,400,474 3,557,428 156,954 3,565,157 164,683
IV Mechanical 8,107,244 9,458,009 1,350,765 9,647,106 1,539,862
V Electrical 551,292 660,034 108,742 632,789 81,497
VI Buildings & Structures 2,998,989 3,080,381 81,392 3,047,653 48,664
VII Engineering & Plant Startup 6,112,089 6,326,665 214,576 6,399,382 287,293
Subtotal - Contractor's Internal Cost 96,425,897 101,215,588 4,789,691 101,179,987 4,754,090
VIII Contractor's Soft & Miscellaneous Costs 12,289,815 12,984,060 694,245 13,010,057 720,242
Contractor's Price 108,715,713 114,199,647 5,483,934 114,190,044 5,474,331
IX Owner's Soft & Miscellaneous Costs 9,784,414 10,277,968 493,554 10,277,104 492,690
Total - Owner's Cost 118,500,127 124,477,616 5,977,489 124,467,148 5,967,021
Gas Turbine Output - kW 157,185 176,293 19,108 176,293 19,108
Steam Turbine Output - kW 91,124 94,180 3,056 90,766 -358
Net Plant Output - kW 242,306 260,834 18,528 260,312 18,006
Net Plant Heat Rate - BTU/ kWH - (LHV) 6,261 6,360 99 6,373 112
Chiller Comparison
Summary
Chiller - Base Case Electric Chiller Steam Chiller
Project Cost Summary Reference Cost Reference Cost Reference Cost
I Specialized Equipment 71,384,700 73,589,300 2,204,600 73,620,300 2,235,600
II Other Equipment 3,871,109 4,543,770 672,662 4,267,599 396,491
III Civil 3,400,474 3,557,428 156,954 3,565,157 164,683
IV Mechanical 8,107,244 9,458,009 1,350,765 9,647,106 1,539,862
V Electrical 551,292 660,034 108,742 632,789 81,497
VI Buildings & Structures 2,998,989 3,080,381 81,392 3,047,653 48,664
VII Engineering & Plant Startup 6,112,089 6,326,665 214,576 6,399,382 287,293
Subtotal - Contractor's Internal Cost 96,425,897 101,215,588 4,789,691 101,179,987 4,754,090
VIII Contractor's Soft & Miscellaneous Costs 12,289,815 12,984,060 694,245 13,010,057 720,242
Contractor's Price 108,715,713 114,199,647 5,483,934 114,190,044 5,474,331
IX Owner's Soft & Miscellaneous Costs 9,784,414 10,277,968 493,554 10,277,104 492,690
Total - Owner's Cost 118,500,127 124,477,616 5,977,489 124,467,148 5,967,021
Gas Turbine Output - kW 157,185 176,293 19,108 176,293 19,108
Steam Turbine Output - kW 91,124 94,180 3,056 90,766 -358
Net Plant Output - kW 242,306 260,834 18,528 260,312 18,006
Net Plant Heat Rate - BTU/ kWH - (LHV) 6,261 6,360 99 6,373 112
Chiller Comparison
Summary
Chiller - Base Case Electric Chiller Steam Chiller
Project Cost Summary Reference Cost Reference Cost Reference Cost
I Specialized Equipment 71,384,700 73,589,300 2,204,600 73,620,300 2,235,600
II Other Equipment 3,871,109 4,543,770 672,662 4,267,599 396,491
III Civil 3,400,474 3,557,428 156,954 3,565,157 164,683
IV Mechanical 8,107,244 9,458,009 1,350,765 9,647,106 1,539,862
V Electrical 551,292 660,034 108,742 632,789 81,497
VI Buildings & Structures 2,998,989 3,080,381 81,392 3,047,653 48,664
VII Engineering & Plant Startup 6,112,089 6,326,665 214,576 6,399,382 287,293
Subtotal - Contractor's Internal Cost 96,425,897 101,215,588 4,789,691 101,179,987 4,754,090
VIII Contractor's Soft & Miscellaneous Costs 12,289,815 12,984,060 694,245 13,010,057 720,242
Contractor's Price 108,715,713 114,199,647 5,483,934 114,190,044 5,474,331
IX Owner's Soft & Miscellaneous Costs 9,784,414 10,277,968 493,554 10,277,104 492,690
Total - Owner's Cost 118,500,127 124,477,616 5,977,489 124,467,148 5,967,021
Gas Turbine Output - kW 157,185 176,293 19,108 176,293 19,108
Steam Turbine Output - kW 91,124 94,180 3,056 90,766 -358
Net Plant Output - kW 242,306 260,834 18,528 260,312 18,006
Net Plant Heat Rate - BTU/ kWH - (LHV) 6,261 6,360 99 6,373 112
Significant Cost Differences
No Chiller vs. Electric and Absorption Chillers
Chiller - Base Case Electric Chiller Steam Chiller
I Specialized Equipment 71,384,700
2. Steam Turbine Package 12,814,000 13,063,000 249,000 12,978,000 164,000
3. Heat Recovery Boiler 10,581,000 10,934,000 353,000 10,834,000 253,000
4. Water-cooled Condenser 954,000 978,300 24,300 913,900 -40,100
Main Chiller Unit 936,500 936,500 1,318,000 1,318,000
Chilling / Heating Water Coil 599,300 599,300 570,300 570,300
10. Transmission Voltage Equipment 2,675,000 2,690,000 15,000 2,673,000 -2,000
11. Generating Voltage Equipment 2,548,000 2,573,000 25,000 2,521,000 -27,000
II Other Equipment 3,871,109 -3,871,109
1. Pumps
HP Feedwater Pump 461,100 463,200 2,100 463,200 2,100
IP Feedwater Pump 289,050 292,200 3,150 292,200 3,150
LP Feedwater Pump 12,480 12,780 300 12,780 300
Condensate Forwarding Pump 21,260 22,040 780 20,020 -1,240
Condenser C.W. Pump 310,200 351,600 41,400 346,000 35,800
GT Inlet Air Chiller/ Heater Water Pump 0 78,150 78,150 31,910 31,910
GT Chiller Coolant Pump 0 59,640 59,640 104,900 104,900
3. Cooling Tower 939,200 1,086,000 146,800 1,082,000 142,800
13. Medium Voltage Equipment 308,700 585,500 276,800 338,750 30,050
14. Low Voltage Equipment 213,700 238,550 24,850 237,900 24,200
15. Miscellaneous Equipment 184,339 216,370 32,032 203,219 18,881
III Civil 3,400,474 3,557,428 156,954 3,565,157 164,683
Chiller - Base Case Electric Chiller Steam Chiller
IV Mechanical 8,107,244 -8,107,244
HRSG 1,891,500 2,017,750 126,250 2,006,650 115,150
Electrical Power Equipment 209,190 232,540 23,350 228,450 19,260
Inlet Chilling System 0 11,927 11,927 14,704 14,704
Pumps 76,050 88,660 12,610 88,980 12,930
Miscellaneous 221,170 231,290 10,120 230,010 8,840
3. Piping
High Pressure Steam 328,100 329,500 1,400 328,800 700
Cold Reheat Steam 109,800 110,260 460 110,080 280
Hot Reheat Steam 344,190 346,190 2,000 345,390 1,200
Low Pressure Steam 75,200 91,520 16,320 91,400 16,200
Circulating Water 331,760 332,950 1,190 332,950 1,190
Auxiliary Cooling Water 472,080 828,310 356,230 1,045,320 573,240
Feedwater 273,410 324,220 50,810 323,150 49,740
Other Water 0 0 0
GT Inlet Chilling/ Heating System 0 615,020 615,020 605,450 605,450
Miscellaneous 231,970 311,660 79,690 327,330 95,360
V Electrical 551,292
1. Assembly & Wiring
Switchgear 9,690 19,420 9,730 10,380 690
Motor Control Centers 17,390 23,690 6,300 20,100 2,710
Feeders 120,800 156,100 35,300 140,450 19,650
Medium/ Low Voltage Cable Bus 139,400 169,750 30,350 169,150 29,750
Cable Tray 84,860 102,700 17,840 103,050 18,190
General Plant Instrumentation 89,220 91,740 2,520 95,180 5,960
Miscellaneous 27,480 32,800 5,320 31,480 4,000
VI Buildings
1. Turbine Hall 2,325,445 2,393,977 68,532 2,361,249 35,804
2. Administration, Control Room, Machine Shop / Warehouse 662,780 675,640 12,860 675,640 12,860
VII Engineering & Startup
1. Engineering 5,442,000 5,631,000 189,000 5,698,000 256,000
2. Start-Up 670,089 695,665 25,576 701,382 31,293
Evaluation of Chillers -
Electric (water or air cooled)
• Go to screen then to the tab
• Choose the type of chiller in the Chiller Options
dropdown box
• Enter the desired temperature drop and inlet air
pressure drops in the appropriate boxes.
• Use a reasonable “Air approach to chilled water”
value (keep above freezing)
• Use appropriate COP
• Choose desired heat sink
Evaluation of Chillers -
Electric (water or air cooled)
• Go to screen then to the tab
• Choose the type of chiller in the Chiller Options
dropdown box
• Enter the desired temperature drop and inlet air
pressure drops in the appropriate boxes.
• Use a reasonable “Air approach to chilled water”
value (keep above freezing)
• Use appropriate COP
• Choose desired heat sink
Absorption (steam driven) as above, but
• Select the steam pressure(s) and source from
the appropriate location
• If steam is extracted from your plant’s steam system,
make appropriate extractions from
As with any enhancement to improve the power plant
performance, the cost and performance impact is more
than simply adding major pieces of equipment.
Their inclusion will affect other
• hardware,
• auxiliary equipment,
• electrical loads,
• installation and startup,
• schedule,
• civil works
~~GT PRO~
GTPRO ~
allows
allowsthe
thepower
powerplant
plantdesigner
designertotoevaluate
evaluatethese
theseimpacts
impacts
quickly
quicklyand
andefficiently.
efficiently.
