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AE94.2 UPGRADING PROJECT
Stefano Traverso
Federico Bonzani
Product Development AE94.2 Project Manager Head of Turbomachinery
[email protected] [email protected]
19th AE94.2 AE94 2 Users Conference Kuala Lumpur, December 2nd 2010
Contents
New development for Ansaldo Energia AE94.2 F Frame Development D l t and dP Product d tO Overview i AE94.2-Evo1 details AE94.2-Evo2 overview Summaryy and Conclusion
Ansaldo Enegia 2010. All rights reserved
Pag. 1
Contents
New development for Ansaldo Energia AE94.2 Frame F Development D l t and d Product P d t Overview O i AE94.2-Evo1 details AE94.2-Evo2 overview Summaryy and Conclusion
Ansaldo Enegia 2010. All rights reserved
Pag. 2
Product Development Roadmap
Availability Optimized
1090°C 33MAC 1075°C 33MAC
UP TO 1075 1075°C C 41MAC
1060°C 41MAC Future Upgrades
Evo olution
AE94 2 Evo2 AE94.2-Evo2 AE94.2-Evo1 New Compressor
AE94 2 6+ AE94.2-6+ 94.2-6
HCO
Opt. HGP components.
94.2-3 94.2 3
TT1+ TT1
p p Opt.Comp.
New Burner 15ppm (methane)
Basis
CMF+
1075°C
1090°C
1060°C
1075°C
1999÷2004
2007
2010
New 3D Turbine B&V
1090°C
2013
Year of introduction Ansaldo Enegia 2010. All rights reserved
Pag. 3
Technical Features for new AE94.2 Evo1/Evo2 Evo1/2
Evo1/2
Mixing chamber (HW3 package) extensive TBC protecting layer
Burner (HW7 package) 15ppm@1090°CISO
Evo2
Turbine (HW4 package) New AE3D Turbine (I-IV stages) Turbine (HW2 package)
Evo1
Evo2
Optimized p Turbine ((I-II stages) g )
Compressor (HW5 package) New AE3D Compressor (I-V stages)
Hot Gas Casing (HW3 package) Evo1/2
Upgrades Packages over AE94.2 AE94 2 units it
extensive TBC protecting layer Optimized cooling flows
TT1 1090° 1090°C or o MAC41@up to 1075° 1075°C Ansaldo Enegia 2010. All rights reserved
Pag. 4
AE94.2 : Development Packages Benefits
GT Version
94.2-6
94.2-6+
94.2-Evo1
94.2-Evo2
ΔTT1
+15°C 15°C
+15°C 15°C
+30°C 30°C
+30°C 30°C
ΔPower(*)
+7.3MW
+10.6MW
+14.6MW
+29MW
ΔEfficiency(*)
+0.2pt%
+0.5pt%
+0.6pt%
+2.0pt%
2004
2008
2010
2013
Availability
Benefit expected over 94.2-3@1060°C @ Single Cycle, ISO conditions, Natural gas firing
-
Upgrading Packages
TT1+
TT1+
CMF+
CMF+
HCO
Hydraulic Clearence Optimisation
6+ HW2 HW3
IGV & CV16 Optimized Enhanced Turbine B&V coatings Enhanced inner casing coatings Enhanced mixing chamber coatings
HW7
New Burner 15ppm (methane)
HW5
New 3D compressor
HW4
New 3D turbine Blades & Vanes
All Upgrades Packages are Fully Retrofittable over 94.2-3 / 94.2-6 Ansaldo Enegia 2010. All rights reserved
Pag. 5
Contents
New development for Ansaldo Energia AE94.2 F Frame Development D l t and dP Product d tO Overview i AE94.2 AE94.2--Evo1 details AE94.2-Evo2 overview Summaryy and Conclusion
Ansaldo Enegia 2010. All rights reserved
Pag. 6
HW2 : Vanes and Blades package
New coatings (BC and TBC) TARGETS ¾ Improve thermo-mechanical behavior ¾ +15°C TT1 @ 33MAC ¾ +5°C TT1 @ 41MAC Vane #1
¾ Potential life extension for Blade 1 and Blade 2.
Vane #2
33MAC @ 1090°C 41MAC @ 1065°C
Blade #1
New HW2 vs previous design
Blade #2 Ansaldo Enegia 2010. All rights reserved
Pag. 7
HW3 : Improved combustion chamber
New coatings on IC and MC
Reduced thermal stresses Improved I d reliability li bilit Inner casing
Reduced damages Reduced Red ced maintenance cost
Mixing chamber Ansaldo Enegia 2010. All rights reserved
Pag. 8
HW7 : New Low NOx Burner
Benefit (natural gas firing) Compared to HR3-Burner further NOx reduction NOx emission below 15ppm Enhanced combustion stability Further F rther flashback resistance Scope New diagonal swirler Enhanced pilot flame system Enhanced ignition system
Ansaldo Enegia 2010. All rights reserved
Pag. 9
AE94.2 Evo1 : Summary
Upgrade Scope (HW2 & HW3 upgrade packages) ¾ Advanced coatings (BC & TBC) on turbine blades and vanes ¾ Advanced coatings (BC & TBC) on mixing chamber and inner casing ¾ New advanced low NOx burner for natural gas firing Benefit ¾ Turbine inlet temperature increase from 1075°C 1075 C to 1090°C 1090 C Open/Combined cycle improvements: Increase in GT power output Increase in GT exhaust energy / Combined Cycle efficiency NOx emission below 15ppm (natural gas firing) ¾ Maintenance Interval Extension 41MAC @ 1065°C (for base load units): Increased efficiency & power output (+5°C TT1 respect to MAC41@ 1060°C) Reduction of maintenance costs Ansaldo Enegia 2010. All rights reserved
Pag. 10
Contents
New development for Ansaldo Energia AE94.2 F Frame Development D l t and dP Product d tO Overview i AE94.2-Evo1 details AE94.2 AE94.2--Evo2 overview Summaryy and Conclusion
Ansaldo Enegia 2010. All rights reserved
Pag. 11
HW4 : New AE3D GT Blades & Vanes
New aerodynamic features y ¾ Reduced stage losses by fully 3D design ¾ reduction of trailing edge thickness ¾ Expansion line optimization
8 completely l t l new 3D blades bl d & Vanes V New GT application on Evo2 Retrofit on AE94.2-3 and AE94.2-6 Increased power and efficiency Increased maintenance intervals @1075°C (41MAC@1075°C)
Ansaldo Enegia 2010. All rights reserved
Pag. 12
HW4 : AE3D Performance Benefits
Fully y Retrofittable over 94.2-3 / 94.2-6 Optimized 3D aerodynamic d i airfoil design
AE3D AE3D AE3D AE3D 3 AE3D
Enhanced base material and coatings
AE3D Reduced cooling/leakage air flows
AE3D AE3D
(*) P Power
GT +8 MW Efficiency(*) GT +1.2pt%
AE3D AE3D
(*) expected values for 94.2-6 upgrade @1075°C ISO conditions, Single Cycle, Methane firing. Ansaldo Enegia 2010. All rights reserved
Pag. 13
HW4 : Roadmap toward AE3D Turbine B&V
12/13 : Product Validation 04/13 : AE3D Turbine Blades & Vanes available 04/12 : Product commercialization 09/10 : Concurrent Engineering with casting g suppliers pp start 01/10 : Product specification 03/09 : Project Start
Ansaldo Enegia 2010. All rights reserved
Pag. 14
HW5 : Fully 3D Compressor Blades & Vanes
9 Five front stages g fully y 3D design g 9 Completely retrofitable on AE94.2 range gas turbine with same rotor di k too disks 9+4% inlet mass flow @same efficiency 9 Low mass flow variations against ambient temperature 9 High turndown capabilities 9 Wet W t compression i capabilities biliti
A il 12 : P April Product d t commercialization i li ti Ansaldo Enegia 2010. All rights reserved
Pag. 15
AE94.2 Evo2 : Summary
Upgrade Scope (HW4, HW3 and HW5 upgrade packages) ¾ New Ansaldo Energia 3D turbine blades and vanes, ¾ New aerodynamic optimized 1-5 compressor stages, ¾ Advanced coatings (BC & TBC) on mixing chamber and inner casing Benefit ¾ Evo2 Turbine inlet temperature fixed to 1090°C 1090 C +10.0% increased power output in Simple Cycle(*) +8.0% 8.0% increased power output in Combined cycle(**) cycle( ) more than +1.4pt% increased efficiency in Simple Cycle (Up to 4.0% higher exhaust mass flow provide more power output in case of existing combined cycle or combined cycle extension compared to HW4 package only) Maintenance Interval Extension @ 1075°C (41MAC for base load units)
(*) ISO conditions, methane firing
(**) w/o design limit in Combined plant parts Ansaldo Enegia 2010. All rights reserved
Pag. 16
Contents
New development for Ansaldo Energia AE94.2 F Frame Development D l t and dP Product d tO Overview i AE94.2-Evo1 details AE94.2-Evo2 overview y and Conclusion Summary
Ansaldo Enegia 2010. All rights reserved
Pag. 17
Summary & Conclusion
Ansaldo Energia Upgrade present and future packages for AE94 AE94.2 2 have been presented. All upgrade packages are modular, can be combined and are completely retrofitable. Extended maintenance interval MAC41 up to 1075°C ISO (by HW2 or HW4 and d HW3 packages). k ) Decreasing combustion emissions by new VeLoNoxTM low NOx Burner (15ppm for methane firing units) units). Further development is ensured.
Ansaldo Enegia 2010. All rights reserved
Pag. 18
AE94.2 UPGRADING PROJECT
MANY THANKS FOR YOUR ATTENTION
19th AE94.2 AE94 2 Users Conference Kuala Lumpur, December 2nd 2010
