1. Ansaldo Energia: Gas Turbine an enabler for intermittent power
Daniela Gentile
Ansaldo Energia Innovation and Product Development
Marsh Power Forum
Security of Supply
Istanbul, October 9-10th, 2013

2. Scenario
Trends of Italian Electricity Market
Future Scenario and Impact on Combined Cycle
Ansaldo Energia Activities & Solutions
Combustion Stability
Lifing & Materials
Control System
Instrumentation
Conclusion

3. Energy Production Sources Mix
Trends of Italian Electricity Market
Energy Production Sources Mix
EVOLUTION FROM 2008 TO 2012
347
328
72%
62%
Source: Terna, Monthly Report on Electric System
Energy Production Sources in Italy, GWh

4. steady decrease of 3-4% per year since 2008
Trends of Italian Electricity Market
Thermal Power Plants Monthly Energy Production (all fuels)
~ 6 GWh/month less since 2008
12-month moving average
Source: Terna, Monthly Report on Electric System
steady decrease of 3-4% per year since 2008

5. …in 3 years thermal PP production share in peak hour
Trends of Italian Electricity Market
PEAK SHAVING: From August 2010 to August 2013…
2010
2013
70%
45%
Source: Terna, Monthly Report on Electric System
…in 3 years thermal PP production share in peak hour
from 70% to 45%

6. Impact of the New Scenario on Combined Cycle
Future Scenario and Impact on Combined Cycle
Impact of the New Scenario on Combined Cycle
Efficiency Increase -> CO2 emission reduction
Minimum Load Reduction -> to enable the feed in of additional RES (renewable energy sources) without a loss of security of supply and grid stability
Startup Time Reduction -> more gas fired power plants could start and stop twice a day economically -> additional RES
Load Ramp Rate Increase -> to promptly react to request or RES generation variations, assuring grid stability and security

7. Scenario
Trends of Italian Electricity Market
Future Scenario and Impact on Combined Cycle
Ansaldo Energia Activities & Solutions
Combustion Stability
MEL
Grid Support
Start-Up time reduction
Material Lifing
Instrumentation
Conclusion

8. Flexibility Packages Start-Up Time Combustion Stability Reduction
MEL
Start-Up Time
Reduction
Grid Support

9. Flexibility Packages Start-Up Time Combustion Stability Reduction
MEL
Start-Up Time
Reduction
Grid Support

10. Combustion Stability: SAS UP UPGRADING & Tests
Ansaldo Energia Activities & Solutions
Combustion Stability
Combustion Stability: SAS UP UPGRADING & Tests
Combustion Chamber cooling optimization
Different burner configurations tested
Control Valves GV2-3
Variable setpoint connected with Load & Ambient Temperature
Burner Insert redesign
Holes reduction
TBC Increasing
Upgraded combustion system
Combustion Chamber
Internal housing Holes reduction to cool the brick holders of the ceramic tiles
Sealing Ring TV2 improved design
External Housing Combustion Chamber
Reduction diameter of the cooling holes

11. TIT ISO NOx Emissions [mg/Nm3]
Ansaldo Energia Activities & Solutions
Combustion Stability
GT & CC Performance (Power & Efficiency)
TIT ISO Increase
POWER MODE
TIT ISO
ENVIRONMENTAL MODE 20 30 40 50
NOx Emissions [mg/Nm3]

12. Helmholtz resonators in combustion chamber
To Control Thermoacoustic Phenomena in order to reduce Combustion Instability
1st prize Finmeccanica Innovation Award 2013
New improved design has been tested on La Casella GT in 2012
AEN patent under application
Application on Escatron GT for commercial operation on March 2014
Ansaldo Energia reserves all right on this document that cannot be
reproduced in any part without its previous written consent

13. 9LS Diagonal swirler Dual Lines Premix Burner
Ansaldo Energia Activities & Solutions
Additional premix line : 20 nozzles
Dual Lines Pilot Burnerrner
Premix line: 20 vanes, 9 holes each
Diffusion Pilot
4 feeding pipes
Premixed pilot
4 holes pattern

14. Flexibility Packages Start-Up Time Combustion Stability Reduction
MEL
Start-Up Time
Reduction
Grid Support

15. AE94.3A4 Flexibility Packages: MEL reduction
HR3
165 MW
AE.94.3A2
HR3
NOx < 50 mg/Nm3
Emissions limits
NOx < 30 mg/Nm3
CO < 30 mg/Nm3
140 MW
AE.94.3A2
VeLoNOx
IGV extra closure
125 MW
AE.94.3A4
VeLoNOx
- 30 MW
CO Catalyst MW
Antiicing
Increasing Secondary Air Flow at Min. Load
- 3÷5 MW
- 8 MW
Regulating Blow-off
Ansaldo Energia reserves all right on this document that cannot be reproduced in any part without its previous written consent

16. Secondary Air Control (SAC)
MEL Reduction
VeLoNOx
New burner with increased and optimized exhaust gas temperature at partial load
2° stage
set-point
Ambient temp.
Norm. Load
Secondary Air Control (SAC)
Variable set point for cooling air flow to GT blades, according to GT load and ambient temperature
HR3
VeLoNOx
VeLoNOx + SAC
GT MEL
60-55 %
48%
43%

17. VeLoNOx + SAC + Anti-icing VeLoNOx + SAC + CO catalyst
MEL Reduction
Anti-icing
Compressor bleed to reduce mass flow and increase inlet temperature
VeLoNOx
VeLoNOx + SAC
VeLoNOx + SAC + Anti-icing
GT MEL
48%
43%
37%
CO Catalyst
Cost for catalyst, installation and maintenance is paid back by fuel saving
VeLoNOx
VeLoNOx + SAC
VeLoNOx + SAC + CO catalyst
GT MEL
48%
43%
30% - 35%

18. Expected performances validated by on-site field measurements
MEL Reduction by Regulating Blow-Off Lines
Goals: Minimum Load reduction according to pollutants emission limits (MEL)
Selected Approach: compressor airflow by-passing burners to sustain combustion temperature at Min Load
Proposed Solution: opening bleeding blow-off lines in regulating mode
Numerical Analysis: GT 1d model + CFD
Field Testing: 5th stage BO line MEL
Expected performances validated by on-site field measurements
(Customer 1 GT, May 2013)
D Power GT [MW]
Dh GT [%]
hrsg inlet temp [°C]
fuel saving [kg/s] -8
-1.4
-7.8
0.25
comparison with Tamb=15°C and same CO concentration
Ansaldo Energia reserves all right on this document that cannot be
reproduced in any part without its previous written consent

19. MEL Evolution 2006 HyperClosure IGV NOx < 25 ppm VeloNOx Burner
165 MW
120 MW
NOx < 15 ppm
150 MW
135 MW
NOx < 25 ppm
125 MW
110 MW
2012
2004
AE94.3A2
2006 HyperClosure IGV
2007
AE94.3A4
2008
GV2 GV3
VeloNOx
Burner
100 MW
2013
SAS Upgraded
2011
94 MW
2014
SAS Upgrading
Regulating Blow Off
Anti-icing

20. Flexibility Packages Start-Up Time Combustion Stability Reduction
MEL
Start-Up Time
Reduction
Grid Support

21. Target matched and improved : 42 MW/min with stable condition
Load Gradient – February 2013
Initial Target 32 MW/min from Minimum Load to 97 % Load
SAS Upgraded GT
NOx Target < 30 mg/Nm3
Load
115275 MW
32 MW/min
Load
115270 MW
42 MW/min
596% BL in 4’ 50 ’’
596% BL in 3’40’’
Combustion Dynamics
Combustion Dynamics
Target matched and improved : 42 MW/min with stable condition
Ansaldo Energia reserves all right on this document that cannot be reproduced in any part without its previous written consent

22. Grid Support Case Study: Congo Island Operation
Scenario:
Project ENI CONGO (Pointe Noire): Country with high instability of grid frequency
Load variation up to 40 MW
Situations with no other power plants on grid
Solution:
Two AE94.2 Gas Turbines,
one in Load Control and one in Speed Control
Solution implemented and successfully tested, running from February, 2011

23. Grid Support: Voltage Regulation Russia Case Study
Scenario
Supply of 11 GT to Russian market
Russian grid: extended and highly unstable. Advanced PSS to comply with Russian regulation
81 Tests with different grid configurations at
NIIPT- Power Transmission Research Institute - labs
Tuned PSS
Solution
PSS (Supplier Ansaldo Sistemi Industriali)
Tuning based on Eigenvalues analysis in a typical configuration of a 4 generators test case required by Russian grid
Il PSS di cui si è curata la taratura è quello del sistema 1
I sistemi 2, 3 e 4 sono regolati in tensione, e rappresentano la rete elettrica “vista da” 1
In particolare il nodo 2 rappresenta uno o più impianti nucleari e il nodo 3 uno o più impianti idroelettrici
Il nodo 4 rappresenta l’equivalente del resto della rete (Nodo a tensione fissata)
Obtained Russian EES Certification

24. Flexibility Packages Start-Up Time Combustion Stability Reduction
MEL
Start-Up Time
Reduction
Grid Support

25. FAST START UP TEST Flame on  95% IGV in 44’ Flame on  125 MW in 32’
Grad.22MW/min
125 MW
Grad. 13 MW/min
Grad.6.5 MW/min
30 MW
Flame on  95% IGV in 44’
Flame on  125 MW in 32’
Ansaldo Energia reserves all right on this document that cannot be
reproduced in any part without its previous written consent 25

26. Conscious ST Startup Time Reduction
Ansaldo Energia Activities & Solutions
Lifing / Materials
Lifing / Materials: ST Flexibility Improvements
Preprocessor: HTC e Tbulk Calculation
FEM Calculation
Postprocessor: LCF Calculation
Test Campaign for Material Properties
RSEOPT: Automatic off-line tool based on FEM calculation
Conscious ST Startup Time Reduction
Power Plant Start-up Curves
Results
Temperature and Stress History
Life Consumption Calculation
Simplified Model
Validation 
Analytical simplified model
Metal temperature & stress calculation
Cycle identification: Rainflow counting method
LCF Life Consumption Calculation
New RSE on Automation System

27. X Control System Packages MEL Ramp Stability Perfor-mance
Ansaldo Energia Activities & Solutions
Control System
MEL
Ramp Stability
Perfor-mance X
Control System Packages
HUMMING ACTIVE CONTROL
Humming Monitoring to improve Combustion Stability Control Logic
Acts on Fuel Valve & TETC control to prevent instability growth
EMISSIONS CONTROL
Integration of exhaust composition measure in control logic
FUEL FLEXIBILITY
Modify the control strategy to rapidly compensate the fuel quality change
Cooling valves control optimization
Cooling valves control optimization based on GT load
Tuning4seasons
Gas / air control optimization based on ambient and operating conditions
Antiicing control
SW modification to enable compressor bleed antiicing for MEL reduction

28. Lifing / Materials: GT Blades & Vanes
Ansaldo Energia Activities & Solutions
Lifing / Materials
Lifing / Materials: GT Blades & Vanes
↑ Efficiency → ↑ TIT ISO
Materials
Coatings
Coolings 2
Cycling Increase 1
Number of Starts (NS)
NS Limit
EOH Limit
Firing Hours

29. Instrumentation More performance & flexibility
Ansaldo Energia Activities & Solutions
Instrumentation
Instrumentation
Innovative humming measurement: piezo or OH detection
More performance & flexibility
More thermomechanical stress
It is essential to monitor the functioning of the components
Innovative humming measurements
Mantova CCPP – 2013
Tip clearance measurements
Micro waves tip clearance instrument
Thrust bearing measurement
Rotor telemetry measures
Compressor
Voghera CCPP – 2013
Thrust Bearing displacement measurements
Mantova CCPP – 2013
Inside GT temperature measurements (compressor & turbine)

30. Flexibility Issue is not a Transient
CONCLUSION
Flexibility Issue is not a Transient
Fast Implementing Solution to support CCPP to cope with Flexibility Requirements
Innovation Project to insure materials and solutions for future upgrading capable to deal with both higher performance and more flexible operation

31. Back-up

32. RENEWABLES GROWTH 2008-2012 (yearly variation):
Trends of Italian Electricity Market
RENEWABLES GROWTH
GSE - Impianti a fonti rinnovabili in Italia: Prima stima 2012 (28/02/2013)
(yearly variation):
+9 TWh wind energy production
+18.6 TWh PV energy production
-17.3 TWh gross energy consumption (-4.9%)
16/06/2013: National Unique Price (PUN) = 0 €/MWh for 2 hours
GME – MGP daily report (16/06/2013)

33. Future Scenario Europe, Horizon 2020: -20% greenhouse gases emissions
Future Scenario and Impact on Combined Cycle
Future Scenario
Strategia Energetica Nazionale: per un’energia più competitiva e sostenibile (March 2013)
Europe, Horizon 2020:
-20% greenhouse gases emissions
+ efficiency
+ cogeneration
California Independent System Operator (CalISO)
Italy, 2020: Towards a Gas / Renewables mix + stability & security from Gas
Example: California prediction for 2020
MW in 2 hours