Ansaldo Energia AE94.2 Upgrading Project

AE94.2 UPGRADING PROJECT

Stefano Traverso Federico BonzaniProduct DevelopmentProduct Development

AE94.2 Project Manager Head of [email protected] [email protected]

19th AE94 2 Users Conference19 AE94.2 Users ConferenceKuala Lumpur, December 2nd 2010

Contents

New development for Ansaldo Energia AE94.2New development for Ansaldo Energia AE94.2

F D l t d P d t O iFrame Development and Product Overview

AE94.2-Evo1 details

AE94.2-Evo2 overview

Summary and Conclusiony

Pag. 1Ansaldo Enegia 2010. All rights reserved

Contents


F D l t d P d t O iF D l t d P d t O iFrame Development and Product OverviewFrame Development and Product Overview

AE94.2-Evo1 details




Product Development Roadmap

1075°C 33MAC1090°C 33MAC

UP TO 1075°C 41MAC

Availability Optimized

AE94 2 Evo2

Future Upgrades

1060°C 41MACUP TO 1075 C 41MAC

AE94 2 6+

AE94.2-Evo1

AE94.2-Evo2

New Compressorolut

ion

94.2-3

94.2-6

AE94.2-6+

TT1+

HCO

Opt.Comp.

Opt. HGP components.

New Burner 15ppm (methane)

New 3D Turbine B&V

1090°CEvo

94.2 3 TT1

CMF+

1075°C

Basis

1060°C

p p

1075°C 1090°C


2010 201320071999÷2004Year of introduction

Technical Features for new AE94.2 Evo1/Evo2

Evo1/2Burner (HW7 package)

15ppm@1090°CISO

Evo1/2Mixing chamber (HW3 package)

Evo2Turbine (HW4 package)

Evo1/2extensive TBC protecting layer

Evo2New AE3D Turbine (I-IV stages)

Evo1Turbine (HW2 package)

Optimized Turbine (I-II stages)

Evo2Compressor (HW5 package)

New AE3D Compressor (I-V stages)

p ( g )

Evo1/2Hot Gas Casing (HW3 package)

extensive TBC protecting layer Optimized cooling flowsOptimized cooling flows

Upgrades Packages Upgrades Packages AE94 2 itAE94 2 it

TT1 1090TT1 1090°°C C or or


over AE94.2 unitsover AE94.2 units ooMAC41@up to 1075MAC41@up to 1075°°CC

AE94.2 : Development Packages Benefits

@

94.2-6 94.2-6+ 94.2-Evo1 94.2-Evo215°C 15°C 30°C 30°C

GT VersionΔTT1 Benefit expected over 94.2-3@1060°C

Single Cycle, ISO conditions, Natural gas firing

+15°C +15°C +30°C +30°C

+7.3MW +10.6MW +14.6MW +29MW

+0.2pt% +0.5pt% +0.6pt% +2.0pt%

ΔTT1

ΔPower(*)

ΔEfficiency(*)

2004 2008 2010 2013Availability- Upgrading Packages

TT1+ TT1+

CMF+ CMF+

HCO Hydraulic Clearence Optimisation

6+ IGV & CV16 Optimized

HW2 Enhanced Turbine B&V coatings

HW3Enhanced inner casing coatings

Enhanced mixing chamber coatings

HW7 New Burner 15ppm (methane)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

Contents



AE94.2AE94.2--Evo1 detailsEvo1 details




HW2 : Vanes and Blades package

New coatings (BC and TBC)

Improve thermo-mechanical behavior

+15°C TT1 @ 33MAC

TARGETS

Vane #1 Vane #2

+15°C TT1 @ 33MAC

+5°C TT1 @ 41MAC

Potential life extension for Blade 1 and Blade 2.

33MAC @ 1090°C

41MAC @ 1065°C


Blade #1 Blade #2New HW2 vs previous design

HW3 : Improved combustion chamber

New coatings on IC and MC

Reduced thermal stresses

I d li bilitImproved reliability

Reduced damages

Red ced maintenance cost

Inner casing

Reduced maintenance cost


Mixing chamber

HW7 : New Low NOx Burner

Benefit (natural gas firing)

Compared to HR3-Burner further NOx reduction

NOx emission below 15ppm

Enhanced combustion stability

F rther flashback resistanceFurther flashback resistance

Scope

New diagonal swirlerNew diagonal swirler

Enhanced pilot flame system

Enhanced ignition system


AE94.2 Evo1 : Summary

Upgrade Scope (HW2 & HW3 upgrade packages)

Advanced coatings (BC & TBC) on turbine blades and vanes

Advanced coatings (BC & TBC) on mixing chamber and inner casing

New advanced low NOx burner for natural gas firingNew advanced low NOx burner for natural gas firing

Benefit

Turbine inlet temperature increase from 1075°C to 1090°CTurbine inlet temperature increase from 1075 C to 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)

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

Contents



AE94.2-Evo1 details

AE94.2AE94.2--Evo2 overviewEvo2 overview



HW4 : New AE3D GT Blades & Vanes

New aerodynamic features

Reduced stage losses by fully 3D design

reduction of trailing edge thickness

y

Expansion line optimization

8 l t l 3D bl d & V8 completely new 3D blades & Vanes

New GT application on Evo2

Retrofit on AE94.2-3 and AE94.2-6 Increased power and efficiencyIncreased maintenance intervals @1075°C (41MAC@1075°C)


HW4 : AE3D Performance Benefits

Fully Retrofittable over 94.2-3 / 94.2-6

Optimized 3D d i

y

Enhanced base

aerodynamic airfoil design

Reduced

AE3D

AE3DAE3D

P (*) GT

Enhanced base material and

coatings

Reduced cooling/leakage

air flows

AE3D

AE3D AE3D

AE3DPower(*) GT

+8 MWEfficiency(*) GT

AE3D

AE3DAE3D

Efficiency GT +1.2pt%AE3D

3

AE3D


(*) expected values for 94.2-6 upgrade @1075°C ISO conditions, Single Cycle, Methane firing.

HW4 : Roadmap toward AE3D Turbine B&V

12/13 : Product Validation

04/13 : AE3D Turbine Blades & Vanes available

04/12 : Product commercialization04/12 : Product commercialization

09/10 : Concurrent Engineering with casting suppliers startg pp

01/10 : Product specification

03/09 : Project Start


HW5 : Fully 3D Compressor Blades & Vanes

Five front stages fully 3D designg y g

Completely retrofitable on AE94.2 range gas turbine with same rotor di kdisks too

+4% inlet mass flow @same efficiencyefficiency

Low mass flow variations against ambient temperatureambient temperature

High turndown capabilities

W t i bilitiWet compression capabilities

A il 12 P d t i li ti


April 12 : Product commercialization

AE94.2 Evo2 : Summary

Upgrade Scope (HW4, HW3 and HW5 upgrade packages)

New Ansaldo Energia 3D turbine blades and vanes,

New aerodynamic optimized 1-5 compressor stages,

Advanced coatings (BC & TBC) on mixing chamber and inner casing

Benefit

Evo2 Turbine inlet temperature fixed to 1090°CEvo2 Turbine inlet temperature fixed to 1090 C

+10.0% increased power output in Simple Cycle(*)

+8.0% increased power output in Combined cycle(**)8.0% increased power output in Combined 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)cycle or combined cycle extension compared to HW4 package only)

Maintenance Interval Extension @ 1075°C (41MAC for base load units)


(**) w/o design limit in Combined plant parts(*) ISO conditions, methane firing

Contents



AE94.2-Evo1 details


Summary and ConclusionSummary and Conclusionyy


Summary & Conclusion

Ansaldo Energia Upgrade present and future packages for AE94 2Ansaldo Energia Upgrade present and future packages for AE94.2 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 HW4 d HW3 k )or HW4 and HW3 packages).

Decreasing combustion emissions by new VeLoNoxTM low NOx Burner (15ppm for methane firing units)Burner (15ppm for methane firing units).

Further development is ensured.


AE94.2 UPGRADING PROJECT

MANY THANKS FOR YOUR ATTENTION

19th AE94 2 Users Conference19 AE94.2 Users ConferenceKuala Lumpur, December 2nd 2010

Ansaldo Energia AE94.2 Upgrading Project

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