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Wallace Manyara

Gas Turbines, the future of South African Power Generation

Avon and Dedisa Power Plants

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Contents

1. Introduction: Ansaldo Energia

2. Gas Turbines

3. Case Study

4. Technology

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Ansaldo Energia: Overview

Revenues by Region

2016 Breakdown, %

17,3%

9,9%

10,9%

30,0%

31,9%

Africa

America

Asia

Europe

Middle East

Revenues

2013-2017, M€

1.219 1.258

1.060

1.253

1.464

2013 2014 2015 2016 2017

Employees

2013-2017, Headcount

3 2673 748

3 505

4 254 4 367

2013 2014 2015 2016 2017

Focus on power generation solutions,

four main business lines:

• OEM Equipment Supply

• Turnkey EPC

• Services

• Nuclear engineering services

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Current recent references (last 10 years)

Ansaldo Energia in Africa

Branch office

Power Plants

COUNTRY SITE TYPE POWER [MW]

ALGERIA AIN DJASSER OC - AE94.2 700

BATNA OC - AE94.2 350

HAMMA OC - AE94.3A 450

HASSI MESSAOUD OC - AE94.3A 650

LABREG OC - AE94.2 500

LARBAA OC - AE94.2 650

M'SILA OC - AE94.3A 550

TERGA CC – GT26 1200

CONGO POINTE NOIRE OC - AE94.2 530

EGYPT 6TH OCTOBER OC - AE94.2 1200

AL SHABAB CC - ST 1500

ALMAHMOUDIA OC - AE94.2 350

BANHA CC - ST 800

EL ATF CC - ST 800

GIZA NORTH CC - ST 2250

SIDI KRIR CC – ST 800

WEST DAMIETTA CC – ST 750

GHANA EFFASU MANGYEA OC – AE64.3A 130

SOUTH AFRICA AVON OC - AE94.2 680

DEDISA OC - AE94.2 340

TUNISIA RADES ST 350

SOUSSE C & D CC - AE94.3A 800

MORNAGUIA OC /AE94.3A 625

GHANNOUCH CC – GT26 400

ZIMBABWE MUTARE OC – AE64.3A 120

TOTAL 17475

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Contents

1. Introduction: Ansaldo Energia

2. Gas Turbines

3. Case Study

4. Technology

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Our Scope of supply in Power Plants

BOP TURNKEY PLANT

TURBINE(S)

GENERATOR(S)

POWER ISLAND(THERMAL CYCLE POWER

EQUIPMENT)

POWER TRAIN

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In Power Generation, Industrial gas turbines are operated in either

• Open cycle - the gas turbine alone is used to drive the generator

• Or in combined cycle - the gas turbine generates power in combination with a

steam turbine, steam cycle, heat recovery generators

Combined cycle power plants

• are more efficient than OC

• Though complex

• Can produce up to 50% more electricity utilizing the same fuel

• Ansaldo GTs are capable of achieving efficiencies close to 63% in CC config

Open cycle power plants

• are less efficient, with thermal efficiencies between 36 and 42%

• they have greater operational flexibility, shorter start times

• load following (ability to increase or decrease power output as the demand for

electricity changes)

Gas Turbines

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GT36-S5 50 Hz

GT36-S6 60 Hz

50 Hz

50 Hz

50 Hz

50 & 60 Hz

GT26

AE94.3A

AE94.2

AE64.3A

370 MW

41%

340 MW

40.3%

190 MW

36.3%

80 MW

36.4%

369 MW

42.3%

538 MW

42.8%

Heavy Duty Gas Turbine Performance

Gas Turbine Portfolio

H Class

H Class

Advanced

F Class

F Class

E Class

Small

F Class

Acquisition of former Alstom Advanced Heavy Duty Gas Turbine Technology

Installed in the Avon and Dedisa Power Plants in South Africa

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The choice of a particular technology (Solar/PV/Wind/Hydro/OCGT/CCGT/Coal) to

generate power depends a number of key factors:

• Cost

• Capacity required and how quickly is it required

• Load factor - % of hours the plant will operate at its maximum capability in a given time

period - Baseload/Load following/ Peaking

• Fuel Flexibility and Operational Flexibility

• Plant scalability options

• Environmental considerations

• Space

• Managing Maintenance

Why Gas Turbines

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Contents

1. Introduction: Ansaldo Energia

2. Gas Turbines

3. Case Study

4. Technology

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Ansaldo Energia in South Africa

AEN role Site GT Type UnitsMW Plant

Commercial Operation

Date

Long Term Service

Agreement

DEDISA EPC Leader & OEMCOEGA IDZ,

P.E.AE94.2 2 340 2015 15 years

AVON EPC Leader & OEM Durban AE94.2 4 680 2016 15 years

DEDISA 340MW

POWER PLANT

AVON 680MW

POWER PLANT

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• Open Cycle, Turnkey EPC Project

• Greenfield Site

• Gas Turbines: 2x170MW Ansaldo Energia AE94.2

• Start of Site Activities: September 2013

• Commercial Operation: September 2015

• Construction Period: 2 years

• Long Term Service Agreement: 15 years

Port Elizabeth, 2 x 170MW Units

DEDISA 340MW Peaking Power Project

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Durban, 4 x 170MW Units

AVON 680MW Peaking Power Project

• Open Cycle, Turnkey EPC Project

• Greenfield Site

• Gas Turbines: 4x170MW Ansaldo Energia AE94.2

• Start of Site Activities: December 2013

• Commercial Operation: July 2016

• Construction Period: 2 years 7 months

• Long Term Service Agreement: 15 years

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2013 2014 2015 2016

Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4

Start of Site Activities / Earthworks

04/14

09/13

11/15

Commissioning & tests

Reopening of Site –Complete Erection

NTP

Sabotage of Unit 108/15

Erection

Civil Construction

12/13

GT1 Synchro

GT4 Synchro

GT3 Synchro

Commercial Operation07/16

Activity

GT2 Synchro

Unit 1 SabotageIssue of Building

PermitNational strike

Avon Project Timeline and organizational challenges

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Durban, 4 x 170MW Units

AVON 680MW Peaking Power Project

• Both plants were designed with a long term view in mind, switch to gas and conversion to a

combined cycle.

• Area for steam generator and steam cycle (steam turbines, generators etc has already been

factored for

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Plant Features

• As much as both plants are functioning as peaking plants on diesel, the plants can

switch to gas when available in South Africa which will

• increase plant efficiency

• Reduce emissions

• Reduce fuel costs

• Gas Turbines installed - AE94.2

• which is a 50hz turbine that operates with a single shaft

• High Starting Reliability – can be used in diverse operating conditions base load,

peaking, different fuels

• Combustion

• The available fuel was diesel (SANS 342) which isn't the best fuel for a gas

turbine

• The design of the AE94.2 combustion system allowed us to diesel as the gas

turbine has two vertical combustion chambers on the side of the gas turbine

• Operation Flexibility – The AE94.2 can respond immediately to variations in power

demand to stabilize local grid frequencies

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AE94.2 – The robust value

2 Silo type Combustion Chambers

16 Compressor stages with inlet variable guide vanes

Rotor Displacement System for gap optimization

Single shaft rotor, disk type with Hirth serration

and central tie rod

Cold end generator driven

4 Turbine stagesAxial discharge

All vanes and blades replaceable with rotor in place

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High Operating Flexibility: fuel options

Special device for crude oil / naphtha / heavy oil:

- Back up fuel (gas or light oil) shall be available for start up / shut down / purging

- Turbine washing device (option) in case of severe fuel contamination (fouling) or Mg inhibitor system

Possibility for mixed mode operation

natural gas / light oil, natural gas / naphtha, ecc.

in 50 – 100 % load range

Fast and reliable fuel change over between fuels

- in a wide load range (from 35 MW up to 95% of base load)

- no need of load reduction (≈ 1%)

- fast change over time (between 2 and 5 minutes)

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Run up time (from standstill to fullspeed no load): < 5 minutes *

High Operating Flexibility: Ramp rates

Normal gradient 11 MW/min

Fast gradient 30 MW/min

Frequency

support80 MW/min

* In open cycle or in combined cycle with boiler purge credit

boiler purge credit available as option

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Capability to burn Special fuels:

H2 or N2 high content gas, LNG, …

Naphtha, Crude Oil, Heavy Fuel Oil, etc.

Low BTU gases with LHV 5 – 15 MJ/kg

(coke oven gas, from steel mill or asphalt gasification process, etc.)

Combustion System

Dry Low Nox combustion for both oil and gas:

AE94.2K

AE94.2

Fuel Gas

supply

conditions

21 bar(g)

Up to 200°C

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Estimated 7 Million EOHProlonged life, Lower cost, better maintainability

America

Chile (1)

Far East

Bangladesh (3)

India (1)

Pakistan (1)

Indonesia (2)

China (3)Middle East

Jordan (2)

Lebanon (2)

Oman (5)

United Arab Emirates (3)

Iran (44)

Africa

Algeria (13)

Congo Rep (3)

Egypt (10)

South Africa (6)

AE94.2 – Maintenance

Europe

Italy (8)

United Kingdom (3)

Finland (3)

Poland (1)

114 Units

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Contents

1. Introduction: Ansaldo Energia

2. Gas Turbines

3. Case Study

4. Technology

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Features to consider for Gas Turbines

• Reduction of emissions

• Increasing gas turbine efficiencies - beyond 63%

• Gas turbines backing up renewable's generation profile

• Hydrogen Combustion Development

• Ansaldo Energia developed a unique, unrivalled, state-of the-art technology

solution that keeps hydrogen combustion under control while preserving

top-level performance.

• Ansaldo Energia has been at the forefront of H2 combustion development

for many years

• Ansaldo Energia gas turbines and retrofit combustors can cope with any

H2-methane blend up to still unmatched maximum H2 volume content of

30, 40 and 50%

• Micro turbines (not so new technology) –currently in the infancy stages in South

Africa can help in distributed generation.

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Constant Pressure Sequential Combustion (CPSC)

Sequantial Combustor GT26/GT 36

Van

e

Tailored to

auto ignition

Very short short

1st combustor Seq. Burner Seq. Combustor

High enough for

CO burnout

Mixer

TIT (ISO 2314/89)

Appr. 1400 ºC

long

−Sequential burner technology allows very low residence times, with good CO

burnout, without staging

−Sequential combustion (with higher secondary burner inlet temperatures and

depleted inlet air O2) permits short residence times for secondary combustor

and potential for ultra low NOx

−NOx emissions at partload are minimal due to the absence of pilot/staging

needs.

Temperature

Residence Time

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Edison SpA – Major operator in the Italian power generation sector, owned by EDF France 153

production plants for a total installed capacity o f 6.1 GW in Italy

(4.6 GW produced by 14 CCGT power plants).

Edison Marghera: THE MOST EFFICIENT POWER PLANT IN EUROPE

Marghera Levante CCGT

• Electric Power: 780 MW

• Efficiency : >63%

• Total Investment : 300 Millions Euros

Ansaldo Energia Supply:

• H-Class GT36-S5 Gas turbine

• HRSG

• Steam Turbine and Generators

• LTSA

• Power Island Contract Signature : 5

March 2019

• CCGT Delivery Time : 3 years

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Gas TurbineGas Turbine

Performance

CCGTConfiguration

(GT + ST)CCGT Power CCGT Efficiency

AE64.3A80 MW

36.4%

1 + 1 120 MW 55.7%

2 + 1 240 MW 56.4%

AE94.2190 MW

36.3%

1 + 1 290 MW 55.8%

2 + 1 580 MW 56.2%

AE94.3A340 MW

40.3%

1 + 1 490 MW 60.0%

2 + 1 990 MW 60.3%

GT26370 MW

41.0%

1 + 1 540 MW 61.0%

2 + 1 1080 MW 61.2%

GT36

(50Hz)

538 MW

42.8%

1 + 1 760 MW 62.6%

2 + 1 1520 MW 62.8%

All Gas Turbines, Steam Turbines and Generators: AEN design and manufacture

Combined Cycle Power Plants

2016: Acquisition of former

Alstom Technology

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100 Kw Micro Turbine

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Thank You

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