Miglioramenti nella flessibilità dei cicli combinati: esperienze recenti di Ansaldo Energia. Alice Pesenti Federico Calzolari

Transcription

1 Miglioramenti nella flessibilità dei cicli combinati: esperienze recenti di Ansaldo Energia Alice Pesenti Federico Calzolari 1

2 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 2

3 ITALIAN ELECTRICAL MARKET SCENARIO Example: California prediction for MW in 2 hours Strategia Energetica Nazionale: per un energia più competitiva e sostenibile (March 2013) California Independent System Operator (CalISO) 3

4 SUMMARY OF AE94.3A4 FLEXIBILITY PACKAGES Package Tested On-going Item Benefit tested Item Benefit exp. Timing MEL Reduction CO Catalyst MW Regulating Blow-off Antiicing -10 MW Cooling Valves -3 5 MW -15 MW (2 B.O.) 12/14 Blow-off open -8 MW (1 B.O.) Grid Support GT Load Gradient HCO ON Fast Unloading Up to 30 MW/min (Up to 42 MW/min with SAS-up) Up to 36 MW/min Humming active control Combustion stability increase (ramps, BL) 06/14 Start-up Time Reduction GT cold load gradient BOP & HRSG logics optimization 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

5 SUMMARY OF AE94.3A4 FLEXIBILITY PACKAGES Package Tested On-going Item Benefit tested Item Benefit exp. Timing MEL Reduction CO Catalyst MW Regulating Blow-off Antiicing -10 MW Cooling Valves -3 5 MW -15 MW (2 B.O.) 12/14 Blow-off open -8 MW (1 B.O.) Grid Support GT Load Gradient HCO ON Fast Unloading Up to 30 MW/min (Up to 42 MW/min with SAS-up) Up to 36 MW/min Humming active control Combustion stability increase (ramps, BL) 06/14 Start-up Time Reduction GT cold load gradient BOP & HRSG logics optimization 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

6 MEL REDUCTION: TESTED PACKAGES Anti-Icing + cooling valves + CO Catalyst ANTI-ICING CATALIZZATORE Δ LOAD [MW] 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) COMBINED CATALYST + ANTI-ICING: -41MW Load=25% P nom. / h TG =21% 6

7 MEL REDUCTION: TESTED PACKAGES Anti-Icing + Cooling Valves + CO Catalyst 25% P nom. 7

8 MEL REDUCTION: TESTED PACKAGES Blow-Off valves: A1.I opened -8MW CO/NOx<30 mg/nm 3 8

9 SUMMARY OF AE94.3A4 FLEXIBILITY PACKAGES Package Tested On-going Item Benefit tested Item Benefit exp. Timing MEL Reduction CO Catalyst MW Regulating Blow-off Antiicing -10 MW Cooling Valves -3 5 MW -15 MW (2 B.O.) 12/14 Blow-off open -8 MW (1 B.O.) Grid Support GT Load Gradient HCO ON Fast Unloading Up to 30 MW/min (Up to 42 MW/min with SAS-up) Up to 36 MW/min Humming active control Combustion stability increase (ramps, BL) 06/14 Start-up Time Reduction GT cold load gradient BOP & HRSG logics optimization 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

10 LOAD GRADIENT: SAS-UP CONFIGURATION Combustion Chamber cooling optimization Upgraded combustion system Control Valves GV2-3 Variable setpoint connected with Load & Ambient Temperature Burner Insert redesign Holes reduction TBC Increasing 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 10

11 GT LOAD GRADIENT IMPROVEMENT Load Ramp Test: Initial Target 32 MW/min from Minimum to 97% Load NOx Target < 30 mg/nm 3 (Diffusion Pilot Burners + SAS up) Target matched and improved: 42 MW/min with stable condition MW 32 MW/min Load MW 42 MW/min Load Combustion Dynamics Combustion Dynamics 11

12 GT LOAD GRADIENT IMPROVEMENT Fast Unloading load rate increase with HCO on Unloading 100% 5% 36MW/min No impact on bearing vibration and combustion stability Clearance monitoring OK 12

13 SUMMARY OF AE94.3A4 FLEXIBILITY PACKAGES Package Tested On-going Item Benefit tested Item Benefit exp. Timing MEL Reduction CO Catalyst MW Regulating Blow-off Antiicing -10 MW Cooling Valves -3 5 MW -15 MW (2 B.O.) 12/14 Blow-off open -8 MW (1 B.O.) Grid Support GT Load Gradient HCO ON Fast Unloading Up to 30 MW/min (Up to 42 MW/min with SAS-up) Up to 36 MW/min Humming active control Combustion stability increase (ramps, BL) 06/14 Start-up Time Reduction GT cold load gradient BOP & HRSG logics optimization 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

14 GT COLD LOAD GRADIENT FSNL 13 MW/min 13 MW/min OK MW in 9 min 14

15 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 15

16 CONCLUSIONS: GT LOAD RANGE UPGRADE 40 % 50 % % 57 % Turano Moncalieri >75 % 65 % Ferrera La Casella 30 % 2006 Escatron 2004 Nox < 50 mg/nm3 Nox < 30 mg/nm3 16

17 CONCLUSIONS: GT LOAD GRADIENT UPGRADE +90% 2008 Ravenna +150% 2009 Rizziconi +220% 2013 La Casella MW/min 17

18 CONCLUSIONS: START UP TIME REDUCTION min - Automatic Sequence - Improved By-pass Management 80 min GT cold load gradient: 13 MW/min - HRSG start-up ramp optimization - ST start-up time optimization 50 min min New ST Rotor Stress Evaluator 18

19 Thank you for your attention 19

20 BACK-UP 20

21 MINIMUM ENVIRONMENTAL LOAD REDUCTION MEL [MW] Antiicing Main CC & Burner improve AE94.3A2 AE94.3A4 Compressor Bleed: DPower, Cost Efficiency External heat Exchanger: DPower, Efficiency Cost IGV Hyperclosed Velonox EVO Ravenna 2010 Modified CC Cooling La Casella La Casella Best burner performance CO Catalyst High Power, High efficiency Cost, Outage ( 2wks) CO catalyst 2000 Dec 2010 Apr 2012 Jul 2012 Time 21

22 CONTROL SYSTEM PACKAGES HUMMING ACTIVE CONTROL Humming Monitoring to improve Combustion Stability Control Logic Acts on Fuel Valve & TETC control to prevent instability growth MEL Ramp Stability X Performance X 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 Antiicing control SW modification to enable compressor bleed antiicing for MEL reduction X X X X 22

23 ANSALDO «EFFICIENCY» 39,7% 39,8% 2012 ~40% ,7% MW 298 MW >310 MW 39,2% 286 MW MW 23