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AE94.

2 UPGRADING PROJECT

Stefano Traverso

Federico Bonzani

Product Development AE94.2 Project Manager Head of Turbomachinery stefano.traverso@aen.ansaldo.it federico.bonzani@aen.ansaldo.it

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

Contents

New development for Ansaldo Energia AE94.2

Frame Development and Product Overview F D l t dP d tO i AE94.2-Evo1 details AE94.2-Evo2 overview y Summary and Conclusion

Ansaldo Enegia 2010. All rights reserved

Pag. 2

Product Development Roadmap

1090C 33MAC 1075C 33MAC 1060C 41MAC UP TO 1075C 41MAC 1075 C

Availability Optimized

Future Upgrades

Evo olution

AE94.2-Evo2 AE94 2 Evo2 AE94.2-Evo1


New Compressor

AE94.2-6+ AE94 2 6+ 94.2-6 94.2 3 94.2-3 Basis 1060C TT1 TT1+ CMF+ 1075C HCO p p Opt.Comp. 1075C

Opt. HGP components. New Burner 15ppm (methane)

New 3D Turbine B&V

1090C

1090C

19992004

2007

2010

2013
Ansaldo Enegia 2010. All rights reserved Pag. 3

Year of introduction

Technical Features for new AE94.2 Evo1/Evo2


Evo1/2 Burner (HW7 package) 15ppm@1090CISO

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 1090C 1090 o or MAC41@up to 1075C 1075


Ansaldo Enegia 2010. All rights reserved Pag. 4

AE94.2 : Development Packages Benefits

GT Version TT1 Power(*) Efficiency(*) Availability

94.2-6 +15C 15C +7.3MW +0.2pt% 2004

94.2-6+ +15C 15C +10.6MW +0.5pt% 2008

94.2-Evo1 +30C 30C +14.6MW +0.6pt% 2010

94.2-Evo2 +30C 30C +29MW +2.0pt% 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 94.2-3@1060C @ Single Cycle, ISO conditions, Natural gas firing

All Upgrades Packages are Fully Retrofittable over 94.2-3 / 94.2-6


Ansaldo Enegia 2010. All rights reserved Pag. 5

Contents

New development for Ansaldo Energia AE94.2

Frame Development and P d t O F D l t d Product Overview i AE94.2AE94.2-Evo1 details AE94.2-Evo2 overview y Summary and Conclusion

Ansaldo Enegia 2010. All rights reserved

Pag. 6

HW2 : Vanes and Blades package

New coatings (BC and TBC)


TARGETS Improve thermo-mechanical behavior +15C TT1 @ 33MAC +5C TT1 @ 41MAC
Vane #1

Potential life extension for Blade 1 and Blade 2. 33MAC @ 1090C 41MAC @ 1065C

Vane #2

Blade #1

New HW2 vs previous design

Blade #2
Ansaldo Enegia 2010. All rights reserved Pag. 7

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. 8

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. All rights reserved

Pag. 9

AE94.2 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 1075C to 1090C 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 @ 1065C (for base load units): Increased efficiency & power output (+5C TT1 respect to MAC41@ 1060C) Reduction of maintenance costs
Ansaldo Enegia 2010. All rights reserved Pag. 10

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 AE94.2AE94.2-Evo2 overview y Summary and Conclusion

Ansaldo Enegia 2010. All rights reserved

Pag. 11

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 AE94.2-3 and AE94.2-6
Increased power and efficiency Increased maintenance intervals @1075C (41MAC@1075C)

Ansaldo Enegia 2010. All rights reserved

Pag. 12

HW4 : AE3D Performance Benefits

Fully Retrofittable over 94.2-3 / 94.2-6 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 94.2-6 upgrade @1075C ISO conditions, Single Cycle, Methane firing.
Ansaldo Enegia 2010. All rights reserved Pag. 13

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. All rights reserved

Pag. 14

HW5 : Fully 3D Compressor Blades & Vanes

Five front stages fully 3D design g y g Completely retrofitable on AE94.2 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. All rights reserved Pag. 15

AE94.2 Evo2 : Summary

Upgrade Scope (HW4, HW3 and HW5 upgrade packages) New Ansaldo Energia 3D turbine blades and vanes, New aerodynamic optimized 1-5 compressor stages, Advanced coatings (BC & TBC) on mixing chamber and inner casing Benefit Evo2 Turbine inlet temperature fixed to 1090C 1090 C +10.0% increased power output in Simple Cycle(*) +8.0% increased power output in Combined cycle(**) 8.0% cycle( ) more than +1.4pt% increased efficiency in Simple Cycle (Up to 4.0% 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 @ 1075C (41MAC for base load units)

(*) ISO conditions, methane firing

(**) w/o design limit in Combined plant parts


Ansaldo Enegia 2010. All rights reserved Pag. 16

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 Summary and Conclusion y

Ansaldo Enegia 2010. All rights reserved

Pag. 17

Summary & Conclusion

Ansaldo Energia Upgrade present and future packages for AE94 2 AE94.2 have been presented. All upgrade packages are modular, can be combined and are completely retrofitable. Extended maintenance interval MAC41 up to 1075C ISO (by HW2 or HW4 and HW3 packages). d k ) Decreasing combustion emissions by new VeLoNoxTM low NOx Burner (15ppm for methane firing units) units). Further development is ensured.

Ansaldo Enegia 2010. All rights reserved

Pag. 18

AE94.2 UPGRADING PROJECT

MANY THANKS FOR YOUR ATTENTION

19th AE94 2 Users Conference AE94.2


Kuala Lumpur, December 2nd 2010