Miglioramenti nella flessibilità dei cicli combinati: esperienze recenti di Ansaldo Energia Alice Pesenti Federico Calzolari Milano, 08 - 04 -12014 Miglioramenti nella flessibilità dei cicli combinati: esperienze recenti di Ansaldo Energia ITALIAN ELECTRICITY MARKET SCENARIO AE94.3A4 FLEXIBILITY PACKAGES MEL Reduction Grid Support Start-up Time Reduction CONCLUSIONS Milano, 08 - 04 - 2014 2 ITALIAN ELECTRICAL MARKET SCENARIO Example: California prediction for 2020 + 13500 MW in 2 hours Strategia Energetica Nazionale: per un’energia più competitiva e sostenibile (March 2013) California Independent System Operator (CalISO) Milano, 08 - 04 - 2014 3 SUMMARY OF AE94.3A4 FLEXIBILITY PACKAGES Tested On-going Package Item MEL Reduction CO Catalyst -30÷35 MW Antiicing -10 MW Cooling Valves -3÷5 MW Blow-off open -8 MW (1 B.O.) GT Load Gradient Up to 30 MW/min (Up to 42 MW/min with SAS-up) HCO ON Fast Unloading Up to 36 MW/min GT cold load gradient BOP & HRSG logics optimization Grid Support Start-up Time Reduction Milano, 08 - 04 - 2014 Benefit tested Item Benefit exp. Timing Regulating Blow-off -15 MW (2 B.O.) 12/14 Humming active control Combustion stability increase (ramps, BL) 06/14 Up to 13 MW/min Purge credit Up to 20 min Ready Up to 40 min saved New RSE Start-up strategy customization 06/14 4 SUMMARY OF AE94.3A4 FLEXIBILITY PACKAGES Tested On-going Package Item MEL Reduction CO Catalyst -30÷35 MW Antiicing -10 MW Cooling Valves -3÷5 MW Blow-off open -8 MW (1 B.O.) GT Load Gradient Up to 30 MW/min (Up to 42 MW/min with SAS-up) HCO ON Fast Unloading Up to 36 MW/min GT cold load gradient BOP & HRSG logics optimization Grid Support Start-up Time Reduction Milano, 08 - 04 - 2014 Benefit tested Item Benefit exp. Timing Regulating Blow-off -15 MW (2 B.O.) 12/14 Humming active control Combustion stability increase (ramps, BL) 06/14 Up to 13 MW/min Purge credit Up to 20 min Ready Up to 40 min saved New RSE Start-up strategy customization 06/14 5 MEL REDUCTION: TESTED PACKAGES Anti-Icing + cooling valves + CO Catalyst ANTI-ICING CO/NOx [mg/Nm3] TV1 [°C] 0 <30 7,8 -7 <30 12,9 (Tamb 8,3) -34 <30 8,2 -41 <30 14,1 (Tamb 9,0) CATALIZZATORE Δ LOAD [MW] COMBINED CATALYST + ANTI-ICING: -41MW Load=25% Pnom. / Milano, 08 - 04 - 2014 h TG =21% 6 MEL REDUCTION: TESTED PACKAGES Anti-Icing + Cooling Valves + CO Catalyst 25% Pnom. Milano, 08 - 04 - 2014 7 MEL REDUCTION: TESTED PACKAGES Blow-Off valves: A1.I opened -8MW CO/NOx<30 mg/Nm3 Milano, 08 - 04 - 2014 8 SUMMARY OF AE94.3A4 FLEXIBILITY PACKAGES Tested On-going Package Item MEL Reduction CO Catalyst -30÷35 MW Antiicing -10 MW Cooling Valves -3÷5 MW Blow-off open -8 MW (1 B.O.) GT Load Gradient Up to 30 MW/min (Up to 42 MW/min with SAS-up) HCO ON Fast Unloading Up to 36 MW/min GT cold load gradient BOP & HRSG logics optimization Grid Support Start-up Time Reduction Milano, 08 - 04 - 2014 Benefit tested Item Benefit exp. Timing Regulating Blow-off -15 MW (2 B.O.) 12/14 Humming active control Combustion stability increase (ramps, BL) 06/14 Up to 13 MW/min Purge credit Up to 20 min Ready Up to 40 min saved New RSE Start-up strategy customization 06/14 9 LOAD GRADIENT: SAS-UP CONFIGURATION Combustion Chamber cooling optimization 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 Milano, 08 - 04 - 2014 Burner Insert redesign Holes reduction TBC Increasing Sealing Ring TV2 improved design External Housing Combustion Chamber Reduction diameter of the cooling holes 10 GT LOAD GRADIENT IMPROVEMENT Load Ramp Test: Initial Target 32 MW/min from Minimum to 97% Load NOx Target < 30 mg/Nm3 (Diffusion Pilot Burners + SAS up) Target matched and improved: 42 MW/min with stable condition 115270 MW 32 MW/min Load Combustion Dynamics Milano, 08 - 04 - 2014 115270 MW 42 MW/min Load Combustion Dynamics 11 GT LOAD GRADIENT IMPROVEMENT Fast Unloading load rate increase with HCO on Unloading 100% → 5% IGV @ 36MW/min No impact on bearing vibration and combustion stability Clearance monitoringOK Milano, 08 - 04 - 2014 12 SUMMARY OF AE94.3A4 FLEXIBILITY PACKAGES Tested On-going Package Item MEL Reduction CO Catalyst -30÷35 MW Antiicing -10 MW Cooling Valves -3÷5 MW Blow-off open -8 MW (1 B.O.) GT Load Gradient Up to 30 MW/min (Up to 42 MW/min with SAS-up) HCO ON Fast Unloading Up to 36 MW/min GT cold load gradient BOP & HRSG logics optimization Grid Support Start-up Time Reduction Milano, 08 - 04 - 2014 Benefit tested Item Benefit exp. Timing Regulating Blow-off -15 MW (2 B.O.) 12/14 Humming active control Combustion stability increase (ramps, BL) 06/14 Up to 13 MW/min Purge credit Up to 20 min Ready Up to 40 min saved New RSE Start-up strategy customization 06/14 13 GT COLD LOAD GRADIENT FSNLMEL @ 13 MW/min 13 MW/minOK 10125 MW in 9 min Milano, 08 - 04 - 2014 14 BOP & HRSG LOGICS OPTIMIZATION HRSG start-up ramp optimisation: variable GT load gradient as function of HRSG HP drum pressure SAVED UP TO 15’ ST minimum steam conditions for start up (permissives) SAVED UP TO 20’ Better operation of drains and vents to reduce steam lines warming up time SAVED UP TO 5’ Milano, 08 - 04 - 2014 15 CONCLUSIONS: GT LOAD RANGE UPGRADE >75 % 65 % 60 % 57 % 2011 50 % 40 % 2006 30 % 2007 2008 Turano Moncalieri 2012 2014 Ferrera La Casella Escatron 2004 Nox < 50 mg/Nm3 Milano, 08 - 04 - 2014 Nox < 30 mg/Nm3 16 CONCLUSIONS: GT LOAD GRADIENT UPGRADE +220% +150% 2013 +90% 2008 2008 2009 2009 Rizziconi La Casella Ravenna 2004 13 MW/min Milano, 08 - 04 - 2014 17 CONCLUSIONS: START UP TIME REDUCTION 2008 90 min - Automatic Sequence - Improved By-pass Management 80 min 50 min 2010 45 min - GT cold load gradient: 13 MW/min - HRSG start-up ramp optimization - ST start-up time optimization 2013 2014 - New ST Rotor Stress Evaluator Milano, 08 - 04 - 2014 18 Thank you for your attention Milano, 08 - 04 - 2014 19 BACK-UP Milano, 08 - 04 - 2014 20 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 CO catalyst Time 2000 Milano, 08 - 04 - 2014 Dec 2010 Apr 2012 Jul 2012 21 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 X X Antiicing control •SW modification to enable compressor bleed antiicing for MEL reduction Milano, 08 - 04 - 2014 X 22 ANSALDO «EFFICIENCY» ~40% 39,8% 2014 39,7% 2007 39,7% >310 MW 298 MW 2005 39,2% 2012 294 MW 286 MW 2004 280 MW Milano, 08 - 04 - 2014 23
Scarica
