Ansaldo Energia AE94.2 Upgrading Project

November 4, 2017 | Author: vincent8295547 | Category: Gas Turbine, N Ox, Gas Compressor, Energy Technology, Sustainable Technologies
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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) [email protected]°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 [email protected] 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 [email protected]°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) ƒ Compared to HR3-Burner further NOx reduction ƒ NOx emission below 15ppm ƒ Enhanced combustion stability ƒ Further F rther flashback resistance ‰ Scope ƒ New diagonal swirler ƒ Enhanced pilot flame system ƒ 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 ƒ Open/Combined cycle improvements: ƒ Increase in GT power output ƒ Increase in GT exhaust energy / Combined Cycle efficiency ƒ NOx emission below 15ppm (natural gas firing) ¾ Maintenance Interval Extension 41MAC @ 1065°C (for base load units): ƒ Increased efficiency & power output (+5°C TT1 respect to [email protected] 1060°C) ƒ 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 ([email protected]°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 ƒ+10.0% increased power output in Simple Cycle(*) ƒ +8.0% 8.0% increased power output in Combined cycle(**) cycle( ) ƒ 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) ƒ 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

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