Ansaldo Energia: la flessibilità operativa dei cicli combinati coniugata all efficienza energetica

Transcription

1 Ansaldo Energia: la flessibilità operativa dei cicli combinati coniugata all efficienza energetica Federico Calzolari R&D Project Manager Milano, 11 luglio 2013

2 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

3 SCENARIO Electrical Market ITALIAN ELECTRICAL MARKET SCENARIO Produzione lorda (GWh) Eolica Solare (yearly variation): +9 TWh wind energy production TWh PV energy production TWh gross energy consumption (-4.9%) 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)

4 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 MW in 2 hours California Independent System Operator (CalISO)

5 SCENARIO 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

6 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

7 ANSALDO ENERGIA ACTIVITIES & SOLUTIONS Combustion Stability COMBUSTION STABILITY: LA CASELLA MODIFICATIONS & TESTS Combustion Chamber cooling optimization Different burner configurations tested 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

8 TIT ISO ANSALDO ENERGIA ACTIVITIES & SOLUTIONS Combustion Stability GT & CC PERFORMANCE (POWER & EFFICIENCY) TIT ISO Increase Pilot Diffusion Pilot Diffusion + reduction of primary flame mix Pilot Premix Pilot Premix with staging POWER MODE ENVIRONMENTAL MODE NOx Emissions [mg/nm3]

9 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 MW 32 MW/min Load MW 42 MW/min Load Combustion Dynamics Combustion Dynamics

10 ANSALDO ENERGIA ACTIVITIES & SOLUTIONS Combustion Stability MEL [MW] MINIMUM ENVIRONMENTAL LOAD REDUCTION 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) 2000 Dec 2010 Apr 2012 Jul 2012 Time

11 Number of Starts (NS) ANSALDO ENERGIA ACTIVITIES & SOLUTIONS Lifing / Materials LIFING / MATERIALS: GT BLADES & VANES Efficiency TIT ISO Materials Coatings Coolings 2 Cycling Increase NS Limit 1 EOH Limit Firing Hours

12 stress ANSALDO ENERGIA ACTIVITIES & SOLUTIONS LIFING / MATERIALS: ST FLEXIBILITY IMPROVEMENTS RSEOPT: Automatic off-line tool based on FEM calculation Preprocessor: HTC e Tbulk Calculation FEM Calculation B D Postprocessor: LCF Calculation B = C 1 ( max, max ) pseudo elastic curve Cyclic stress strain curve Hysteresis stress - strain curve Neuber s Hyperbola Test Campaign for Material Properties Lifing / Materials A C D D = C 2 A D ep ( min, min ) C' D ep D el C D el Power Plant Start-up Curves Results Temperature and Stress History Life Consumption Calculation Conscious ST Startup Time Reduction Analytical simplified model Metal temperature & stress calculation Cycle identification: Rainflow counting method LCF Life Consumption Calculation New RSE on Automation System

13 ANSALDO ENERGIA ACTIVITIES & SOLUTIONS Control System CONTROL SYSTEM PACKAGES MEL Ramp Stability Performance HUMMING ACTIVE CONTROL Humming Monitoring to improve Combustion Stability Control Logic Acts on Fuel Valve & TETC control to prevent instability growth X 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

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

15 CONCLUSION ANSALDO «EFFICIENCY» +90% % 2009 Rizziconi +220% 2013 La Casella 13 MW/min Ravenna 2004

16 CONCLUSION ANSALDO «EFFICIENCY» 65 % 40 % % % Escatron % 2011 Turano Moncalieri 2012 La Casella 30 % 2004 Nox < 50 mg/nm3 Nox < 30 mg/nm3

17 CONCLUSION ANSALDO «EFFICIENCY» 39,7% 2005 ~40% 39,8% 39,7% OGGI MW 294 MW 2014 >310 MW 39,2% 286,4 MW ,9 MW

18 Federico Calzolari