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

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Presentation on theme: "Ansaldo Energia: Gas Turbine an enabler for intermittent power Marsh Power Forum Security of Supply Istanbul, October 9-10 th, 2013 Daniela Gentile Ansaldo."— Presentation transcript:

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

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

3 TRENDS OF ITALIAN ELECTRICITY MARKET ENERGY PRODUCTION SOURCES MIX EVOLUTION FROM 2008 TO 2012 Energy Production Sources in Italy, GWh %62% Source: Terna, Monthly Report on Electric System

4 TRENDS OF ITALIAN ELECTRICITY MARKET THERMAL POWER PLANTS MONTHLY ENERGY PRODUCTION (ALL FUELS) Source: Terna, Monthly Report on Electric System steady decrease of 3-4% per year since month moving average ~ 6 GWh/month less since 2008

5 TRENDS OF ITALIAN ELECTRICITY MARKET Source: Terna, Monthly Report on Electric System 45% 70% PEAK SHAVING: FROM AUGUST 2010 TO AUGUST 2013… …in 3 years thermal PP production share in peak hour from 70% to 45% …in 3 years thermal PP production share in peak hour from 70% to 45%

6 FUTURE SCENARIO AND IMPACT ON COMBINED CYCLE IMPACT OF THE NEW SCENARIO ON COMBINED CYCLE  Efficiency Increase -> CO 2 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 o Trends of Italian Electricity Market o Future Scenario and Impact on Combined Cycle Ansaldo Energia Activities & Solutions o Combustion Stability o MEL o Grid Support o Start-Up time reduction o Material Lifing o Instrumentation Conclusion

8 Ansaldo Energia Proprietary & Confidential Information Flexibility Packages Combustion Stability MEL Start-Up Time Reduction Grid Support

9 Ansaldo Energia Proprietary & Confidential Information Flexibility Packages Combustion Stability MEL Start-Up Time Reduction Grid Support

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

11 Combustion Stability ANSALDO ENERGIA ACTIVITIES & SOLUTIONS GT & CC PERFORMANCE (POWER & EFFICIENCY) TIT ISO Increase NOx Emissions [mg/Nm3] TIT ISO ENVIRONMENTAL MODE POWER MODE

12 Helmholtz resonators in combustion chamber To Control Thermoacoustic Phenomena in order to reduce Combustion Instability Ansaldo Energia reserves all right on this document that cannot be reproduced in any part without its previous written consent 12 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

13 Diffusion Pilot 4 feeding pipes Premixed pilot 4 holes pattern 9LS Diagonal swirler Dual Lines Premix Burner Premix line: 20 vanes, 9 holes each Additional premix line : 20 nozzles Dual Lines Pilot Burnerrner ANSALDO ENERGIA ACTIVITIES & SOLUTIONS

14 Ansaldo Energia Proprietary & Confidential Information Flexibility Packages Combustion Stability MEL Start-Up Time Reduction Grid Support

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

16  Secondary Air Control (SAC) Variable set point for cooling air flow to GT blades, according to GT load and ambient temperature 2° stage set-point Ambient temp. Norm. Load  VeLoNOx New burner with increased and optimized exhaust gas temperature at partial load HR3VeLoNOxVeLoNOx + SAC GT MEL60-55 %48%43% 16 MEL Reduction

17  Anti-icing Compressor bleed to reduce mass flow and increase inlet temperature VeLoNOxVeLoNOx + SAC VeLoNOx + SAC + Anti-icing GT MEL48%43%37% VeLoNOxVeLoNOx + SACVeLoNOx + SAC + CO catalyst GT MEL48%43%30% - 35%  CO Catalyst Cost for catalyst, installation and maintenance is paid back by fuel saving 17 MEL Reduction

18 Expected performances validated by on-site field measurements (Customer 1 GT, May 2013) 18  Power GT [MW]  GT [%] HRSG INLET TEMP [°C] FUEL SAVING [ KG / S ] COMPARISON WITH T AMB =15°C AND SAME CO CONCENTRATION 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 MEL Reduction by Regulating Blow-Off Lines Ansaldo Energia reserves all right on this document that cannot be reproduced in any part without its previous written consent

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

20 Ansaldo Energia Proprietary & Confidential Information Flexibility Packages Combustion Stability MEL Start-Up Time Reduction Grid Support

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

22 22 Solution implemented and successfully tested, running from February, 2011  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 Grid Support Case Study: Congo Island Operation

23 23 Tuned PSS Obtained Russian EES Certification  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  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 Grid Support: Voltage Regulation Russia Case Study

24 Ansaldo Energia Proprietary & Confidential Information Flexibility Packages Combustion Stability MEL Start-Up Time Reduction Grid Support

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

26 Lifing / Materials ANSALDO ENERGIA ACTIVITIES & SOLUTIONS 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 Power Plant Start-up Curves Results Temperature and Stress History Life Consumption Calculation Analytical simplified model Metal temperature & stress calculation Cycle identification: Rainflow counting method LCF Life Consumption Calculation New RSE on Automation System Conscious ST Startup Time Reduction

27 Control System ANSALDO ENERGIA ACTIVITIES & SOLUTIONS 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 MEL Ramp Stability Perfor- mance XX X XX XX XXX X

28 Lifing / Materials ANSALDO ENERGIA ACTIVITIES & SOLUTIONS LIFING / MATERIALS: GT BLADES & VANES ↑ Efficiency → ↑ TIT ISO Materials Coatings Coolings Number of Starts (NS) Firing Hours Cycling Increase NS Limit 21 EOH Limit

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

30 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 Ansaldo Energia Proprietary & Confidential Information Back-up

32 TRENDS OF ITALIAN ELECTRICITY MARKET RENEWABLES GROWTH (yearly variation): +9 TWh wind energy production TWh PV energy production TWh gross energy consumption (-4.9%) 16/06/2013: National Unique Price (PUN) = 0 €/MWh for 2 hours GSE - Impianti a fonti rinnovabili in Italia: Prima stima 2012 (28/02/2013) GME – MGP daily report (16/06/2013)

33 FUTURE SCENARIO AND IMPACT ON COMBINED CYCLE FUTURE SCENARIO Italy, 2020: Towards a Gas / Renewables mix + stability & security from Gas Example: California prediction for MW in 2 hours Europe, Horizon 2020: -20% greenhouse gases emissions + efficiency + cogeneration Strategia Energetica Nazionale: per un’energia più competitiva e sostenibile (March 2013) California Independent System Operator (CalISO)


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