Ansaldo Energia: la flessibilità operativa dei cicli
combinati coniugata all’efficienza energetica
Federico Calzolari – R&D Project Manager
Milano, 11 luglio 2013
Scenario
o Electrical Market & Future Scenario
o Impact on Combined Cycle
Ansaldo Energia Activities & Solutions
o Combustion Stability
o Lifing & Materials
o Control System
o Instrumentation
Conclusion
SCENARIO
Electrical Market
ITALIAN ELECTRICAL MARKET SCENARIO
Produzione lorda (GWh)
20000
18000
16000
14000
12000
10000
Eolica
8000
Solare
6000
2008-2012 (yearly variation):
• +9 TWh wind energy production
• +18.6 TWh PV energy production
• -17.3 TWh gross energy consumption (-4.9%)
4000
2000
0
2008
2009
2010
2011
2012
GSE - Impianti a fonti rinnovabili in Italia: Prima stima 2012 (28/02/2013)
16/06/2013: National Unique Price (PUN) = 0 €/MWh for 2 hours
GME – MGP daily report (16/06/2013)
SCENARIO
Future Scenario
FUTURE SCENARIO
Europe, Horizon 2020:
-20% greenhouse gases emissions
+ efficiency
+ cogeneration
Strategia Energetica Nazionale: per un’energia più competitiva e sostenibile (March 2013)
Italy, 2020: Towards a Gas /
Renewables mix
+ stability & security from Gas
Example: California prediction
for 2020
+ 13500 MW in 2 hours
California Independent System Operator (CalISO)
SCENARIO
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
Scenario
o Electrical Market & Future Scenario
o Impact on Combined Cycle
Ansaldo Energia Activities & Solutions
o Combustion Stability
o Lifing & Materials
o Control System
o Instrumentation
Conclusion
ANSALDO ENERGIA ACTIVITIES & SOLUTIONS
Combustion Stability
COMBUSTION STABILITY: LA CASELLA MODIFICATIONS & TESTS
 Combustion Chamber cooling optimization
 Different burner configurations tested
Control Valves GV2-3
Variable setpoint connected with Load
& Ambient Temperature
Upgraded combustion system
Combustion Chamber
Internal housing Holes reduction to cool the brick
holders of the ceramic tiles
Burner Insert redesign
Holes reduction
TBC Increasing
Sealing Ring TV2 improved design
External Housing Combustion Chamber
Reduction diameter of the cooling holes
ANSALDO ENERGIA ACTIVITIES & SOLUTIONS
Combustion Stability
GT & CC PERFORMANCE (POWER & EFFICIENCY)
 TIT ISO Increase
Pilot Diffusion
+ reduction of
primary flame
mix
Pilot
Diffusion
TIT ISO
POWER MODE
Pilot
Premix
Pilot Premix
with staging
ENVIRONMENTAL
MODE
20
30
40
NOx Emissions [mg/Nm3]
50
ANSALDO ENERGIA ACTIVITIES & SOLUTIONS
Combustion Stability
GT LOAD GRADIENT IMPROVEMENT
 Load Ramp Test: Initial Target 32 MW/min from Minimum to 97% Load
 NOx Target < 30 mg/Nm3
 Target matched and improved: 42 MW/min with stable condition
115270 MW
32 MW/min
Load
Combustion Dynamics
115270 MW
42 MW/min
Load
Combustion Dynamics
ANSALDO ENERGIA ACTIVITIES & SOLUTIONS
Combustion Stability
MINIMUM ENVIRONMENTAL LOAD REDUCTION
Antiicing
• Compressor Bleed:
DPower, Cost
Efficiency
• External heat Exchanger:
DPower, Efficiency
Cost
+
-
+
-
Main CC & Burner improve
MEL
[MW]
AE94.3A2
CO Catalyst
High ∆Power, High efficiency
Cost, Outage (≈ 2wks)
+
-
IGV Hyperclosed
150
Velonox EVO
AE94.3A4
140
Modified CC Cooling
Ravenna 2010
120
Best burner
performance
La Casella 2012
100
La Casella 2012
95
Time
2000
Dec 2010
Apr 2012
Jul 2012
ANSALDO ENERGIA ACTIVITIES & SOLUTIONS
Lifing / Materials
LIFING / MATERIALS: GT BLADES & VANES
↑ Efficiency → ↑ TIT ISO
• Materials
• Coatings
• Coolings
Number of Starts (NS)
2
Cycling Increase
1
NS Limit
EOH Limit
Firing Hours
ANSALDO ENERGIA ACTIVITIES & SOLUTIONS
Lifing / Materials
LIFING / MATERIALS: ST FLEXIBILITY IMPROVEMENTS
RSEOPT: Automatic off-line tool based on FEM calculation
Preprocessor:
HTC e Tbulk Calculation
Postprocessor:
LCF Calculation
FEM Calculation

pseudo elastic curve
  = C1
Cyclic stress – strain curve
B
Hysteresis stress - strain curve
(max , max )
D
stress
B
A
Test Campaign for
Material Properties
Neuber’s Hyperbola
D D = C2

A
C
D ep
Del
'
(min , min ) C D
ep
C
Power Plant
Start-up Curves
Analytical simplified model
Metal temperature & stress calculation
• Cycle identification: Rainflow counting
method
• LCF Life Consumption Calculation
•
Del
Results
• Temperature and Stress
History
• Life Consumption
Calculation
Conscious
ST Startup
Time
Reduction
New RSE on
Automation System
ANSALDO ENERGIA ACTIVITIES & SOLUTIONS
Control System
CONTROL SYSTEM PACKAGES
MEL
Ramp
Stability
Performance
X
X
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
X
FUEL FLEXIBILITY
•Modify the control strategy to rapidly compensate the fuel quality
change
X
X
Cooling valves control optimization
•Cooling valves control optimization based on GT load
X
X
Tuning4seasons
•Gas / air control optimization based on ambient and operating
conditions
X
Antiicing control
•SW modification to enable compressor bleed antiicing for MEL
reduction
X
X
X
ANSALDO ENERGIA ACTIVITIES & SOLUTIONS
Instrumentation
INSTRUMENTATION
2013 -2014
Innovative humming measurement:
piezo or OH detection
More performance & flexibility
Mantova CCPP – 2013
Tip clearance measurements
More thermomechanical stress
It is essential to monitor the
functioning of the components
Innovative humming measurements
Micro waves tip clearance instrument
Rotor telemetry
measures
Thrust bearing
measurement
Voghera CCPP – 2013
Thrust Bearing
displacement
measurements
Compressor
Mantova CCPP – 2013
Inside GT temperature
measurements (compressor &
turbine)
CONCLUSION
ANSALDO «EFFICIENCY»
+220%
+150%
2013
2009
+90%
2008
Ravenna
13 MW/min
2004
La Casella
Rizziconi
CONCLUSION
ANSALDO «EFFICIENCY»
65 %
60 %
57 %
50 %
2008
2011
2007
40 %
Turano
2012
La Casella
Moncalieri
2006
Escatron
30 %
2004
Nox < 50 mg/Nm3
Nox < 30 mg/Nm3
CONCLUSION
ANSALDO «EFFICIENCY»
~40%
39,8%
39,7%
2007
39,7%
286,4 MW
2004
279,9 MW
>310 MW
298 MW
2005
39,2%
OGGI
294 MW
2014
Federico Calzolari
[email protected]