AE94.2 UPGRADING PROJECT Stefano Traverso Federico Bonzani Product Development AE94.2 Project Manager Head of Turbomachinery [email protected][email protected] 19th AE94 2 Users Conference AE94.2 Kuala Lumpur, December 2nd 2010 Contents New development for Ansaldo Energia AE94.2 Frame Development and P d t O F D l t d Product Overview i AE94.2-Evo1 details AE94.2-Evo2 overview y Summary and Conclusion Ansaldo Enegia 2010. All rights reserved Pag. 1 2 Frame Development and Product Overview F D l t dP d tO i AE94.2-Evo2 overview y Summary and Conclusion Ansaldo Enegia 2010. All rights reserved Pag.Contents New development for Ansaldo Energia AE94. 2 .2-Evo1 details AE94. 2-6 94.2 3 94. New Burner 15ppm (methane) New 3D Turbine B&V 1090°C 1090°C 1999÷2004 2007 2010 2013 Ansaldo Enegia 2010.Product Development Roadmap 1090°C 33MAC 1075°C 33MAC 1060°C 41MAC UP TO 1075°C 41MAC 1075 C Availability Optimized Future Upgrades Evo olution AE94.2-3 Basis 1060°C TT1 TT1+ CMF+ 1075°C HCO p p Opt. 1075°C Opt. HGP components.2-Evo2 AE94 2 Evo2 AE94. 3 Year of introduction .2-Evo1 New Compressor AE94.2-6+ AE94 2 6+ 94.Comp. All rights reserved Pag. 2 Evo1/Evo2 Evo1/2 Burner (HW7 package) 15ppm@1090°CISO Evo1/2 Mixing chamber (HW3 package) extensive TBC protecting layer Evo2 Turbine (HW4 package) New AE3D Turbine (I-IV stages) Turbine (HW2 package) Evo1 Optimized Turbine ( stages) p (I-II g ) Evo2 Compressor (HW5 package) New AE3D Compressor (I-V stages) Hot Gas Casing (HW3 package) Evo1/2 extensive TBC protecting layer Optimized cooling flows Upgrades Packages over AE94 2 units AE94.2 it TT1 1090°C 1090° o or MAC41@up to 1075°C 1075° Ansaldo Enegia 2010. 4 . All rights reserved Pag.Technical Features for new AE94. 6MW +0.0pt% 2013 TT1+ CMF+ HCO 6+ HW2 HW3 HW7 HW5 HW4 TT1+ CMF+ Hydraulic Clearence Optimisation IGV & CV16 Optimized Enhanced Turbine B&V coatings Enhanced inner casing coatings Enhanced mixing chamber coatings New Burner 15ppm (methane) New 3D compressor New 3D turbine Blades & Vanes Upgrading Packages Benefit expected over 94. All rights reserved Pag.2-Evo2 +30°C 30°C +29MW +2. ISO conditions.2 : Development Packages Benefits GT Version ΔTT1 ΔPower(*) ΔEfficiency(*) Availability 94. Natural gas firing All Upgrades Packages are Fully Retrofittable over 94. 5 .6MW +0.2pt% 2004 94.2-6+ +15°C 15°C +10.2-6 Ansaldo Enegia 2010.5pt% 2008 94.3MW +0.AE94.2-6 +15°C 15°C +7.6pt% 2010 94.2-Evo1 +30°C 30°C +14.2-3@1060°C @ Single Cycle.2-3 / 94. 6 .2-Evo2 overview y Summary and Conclusion Ansaldo Enegia 2010.2-Evo1 details AE94. All rights reserved Pag.2AE94.Contents New development for Ansaldo Energia AE94.2 Frame Development and P d t O F D l t d Product Overview i AE94. 7 .HW2 : Vanes and Blades package New coatings (BC and TBC) TARGETS Improve thermo-mechanical behavior +15°C TT1 @ 33MAC +5°C TT1 @ 41MAC Vane #1 Potential life extension for Blade 1 and Blade 2. 33MAC @ 1090°C 41MAC @ 1065°C Vane #2 Blade #1 New HW2 vs previous design Blade #2 Ansaldo Enegia 2010. All rights reserved Pag. 8 .HW3 : Improved combustion chamber New coatings on IC and MC Reduced thermal stresses Improved reliability I d li bilit Inner casing Reduced damages Reduced Red ced maintenance cost Mixing chamber Ansaldo Enegia 2010. All rights reserved Pag. HW7 : New Low NOx Burner Benefit (natural gas firing) Compared to HR3-Burner further NOx reduction NOx emission below 15ppm Enhanced combustion stability Further F rther flashback resistance Scope New diagonal swirler Enhanced pilot flame system Enhanced ignition system Ansaldo Enegia 2010. 9 . All rights reserved Pag. 10 .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 firing Benefit Turbine inlet temperature increase from 1075°C to 1090°C 1075 C 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 Ansaldo Enegia 2010. All rights reserved Pag.AE94. 2-Evo2 overview y Summary and Conclusion Ansaldo Enegia 2010.2-Evo1 details AE94. 11 .2AE94.Contents New development for Ansaldo Energia AE94.2 Frame Development and P d t O F D l t d Product Overview i AE94. All rights reserved Pag. 2-3 and AE94.HW4 : New AE3D GT Blades & Vanes New aerodynamic features y Reduced stage losses by fully 3D design reduction of trailing edge thickness Expansion line optimization blades Vanes 8 completely new 3D bl d & V l t l New GT application on Evo2 Retrofit on AE94.2-6 Increased power and efficiency Increased maintenance intervals @1075°C (41MAC@1075°C) Ansaldo Enegia 2010. 12 . All rights reserved Pag. 2-6 upgrade @1075°C ISO conditions. Single Cycle. Methane firing.2-3 / 94.HW4 : AE3D Performance Benefits Fully Retrofittable over 94. All rights reserved Pag.2-6 y Optimized 3D aerodynamic d i airfoil design Enhanced base material and coatings Reduced cooling/leakage air flows AE3D AE3D AE3D AE3D 3 AE3D AE3D AE3D AE3D GT +8 MW Efficiency(*) GT +1.2pt% Power(*) P AE3D AE3D (*) expected values for 94. 13 . Ansaldo Enegia 2010. 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 suppliers start g pp 01/10 : Product specification 03/09 : Project Start Ansaldo Enegia 2010. 14 . All rights reserved Pag. 15 .HW5 : Fully 3D Compressor Blades & Vanes Five front stages fully 3D design g y g Completely retrofitable on AE94. All rights reserved Pag.2 range gas turbine with same rotor disks di k too +4% inlet mass flow @same efficiency Low mass flow variations against ambient temperature High turndown capabilities Wet W t compression capabilities i biliti April A il 12 : P d t commercialization Product i li ti Ansaldo Enegia 2010. 4pt% increased efficiency in Simple Cycle (Up to 4. methane firing (**) w/o design limit in Combined plant parts Ansaldo Enegia 2010.0% higher exhaust mass flow provide more power output in case of existing combined cycle or combined cycle extension compared to HW4 package only) Maintenance Interval Extension @ 1075°C (41MAC for base load units) (*) ISO conditions. All rights reserved Pag.2 Evo2 : Summary Upgrade Scope (HW4. 16 . Advanced coatings (BC & TBC) on mixing chamber and inner casing Benefit Evo2 Turbine inlet temperature fixed to 1090°C 1090 C +10.0% increased power output in Combined cycle(**) 8.0% increased power output in Simple Cycle(*) +8.0% cycle( ) more than +1.AE94. HW3 and HW5 upgrade packages) New Ansaldo Energia 3D turbine blades and vanes. New aerodynamic optimized 1-5 compressor stages. 2-Evo1 details AE94.2 Frame Development and P d t O F D l t d Product Overview i AE94. All rights reserved Pag.Contents New development for Ansaldo Energia AE94. 17 .2-Evo2 overview Summary and Conclusion y Ansaldo Enegia 2010. can be combined and are completely retrofitable.Summary & Conclusion Ansaldo Energia Upgrade present and future packages for AE94 2 AE94.2 have been presented. d k ) Decreasing combustion emissions by new VeLoNoxTM low NOx Burner (15ppm for methane firing units) units). All upgrade packages are modular. All rights reserved Pag. Extended maintenance interval MAC41 up to 1075°C ISO (by HW2 or HW4 and HW3 packages). Ansaldo Enegia 2010. Further development is ensured. 18 . 2 Kuala Lumpur.2 UPGRADING PROJECT MANY THANKS FOR YOUR ATTENTION 19th AE94 2 Users Conference AE94.AE94. December 2nd 2010 .