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
AE94 2 Users Conference
Kuala Lumpur, December 2nd 2010
Contents

New development for Ansaldo Energia AE94.2

F
Frame Development
D l t and
dPProduct
d tO Overview
i
AE94.2-Evo1 details
AE94.2-Evo2 overview
Summaryy and Conclusion

Ansaldo Enegia 2010. All rights reserved

Pag. 1
Contents

New development for Ansaldo Energia AE94.2

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

Ansaldo Enegia 2010. All rights reserved

Pag. 2
Product Development Roadmap

Availability
1090C 33MAC Optimized
1075C 33MAC UP TO 1075
1075C
C 41MAC
1060C 41MAC
Future
Upgrades
AE94 2 Evo2
AE94.2-Evo2
olution

AE94.2-Evo1
New Compressor
Evo

AE94 2 6+
AE94.2-6+ Opt. HGP New 3D Turbine B&V
components.
94.2-6 HCO 1090C
New Burner 15ppm
94.2-3
94.2 3 TT1+
TT1 p p
Opt.Comp. (methane)

Basis CMF+ 1075C 1090C

1060C 1075C

19992004 2007 2010 2013

Year of introduction
Ansaldo Enegia 2010. All rights reserved
Pag. 3
Technical Features for new AE94.2
Evo1/Evo2
Burner (HW7 package)
Evo1/2
15ppm@1090CISO

Mixing chamber (HW3 package) Turbine (HW4 package)

Evo1/2 Evo2
extensive TBC protecting layer New AE3D Turbine (I-IV stages)

Turbine (HW2 package)

Evo1
Optimized
p Turbine ((I-II stages)
g )

Compressor (HW5 package)

Evo2
New AE3D Compressor (I-V stages)

Hot Gas Casing (HW3 package)

Evo1/2 extensive TBC protecting layer
Optimized cooling flows

TT1 1090
1090C
Upgrades Packages
or
o
over AE94.2
AE94 2 units
it
MAC41@up to 1075
1075C
Ansaldo Enegia 2010. All rights reserved
Pag. 4
AE94.2 : Development Packages Benefits

GT Version 94.2-6 94.2-6+ 94.2-Evo1 94.2-Evo2

TT1 +15C
15C +15C
15C +30C
30C +30C
30C Benefit expected over 94.2-3@1060C
@
Power(*) +7.3MW +10.6MW +14.6MW +29MW Single Cycle, ISO conditions, Natural
gas firing
Efficiency(*) +0.2pt% +0.5pt% +0.6pt% +2.0pt%
Availability 2004 2008 2010 2013
- Upgrading Packages
TT1+ TT1+
CMF+ CMF+
HCO Hydraulic Clearence Optimisation
6+ IGV & CV16 Optimized
HW2 Enhanced Turbine B&V coatings
Enhanced inner casing coatings
HW3
Enhanced mixing chamber coatings
HW7 New Burner 15ppm (methane)
HW5 New 3D compressor
HW4 New 3D turbine Blades & Vanes

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

F
Frame Development
D l t and
dPProduct
d tO Overview
i
AE94.2
AE94.2--Evo1 details
AE94.2-Evo2 overview
Summaryy 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. Vane #2

33MAC @ 1090C
41MAC @ 1065C

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
I d reliability
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
1075 C to 1090C
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

F
Frame Development
D l t and
dPProduct
d tO Overview
i
AE94.2-Evo1 details
AE94.2
AE94.2--Evo2 overview
Summaryy and Conclusion

Ansaldo Enegia 2010. All rights reserved

Pag. 11
HW4 : New AE3D GT Blades & Vanes

New aerodynamic
y features

Reduced stage losses by fully 3D design

reduction of trailing edge thickness
Expansion line optimization

8 completely
l t l new 3D blades
bl d & Vanes
V

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
y Retrofittable over 94.2-3 / 94.2-6

Optimized 3D
aerodynamic
d i
AE3D airfoil design
AE3D
Enhanced base Reduced
AE3D material and cooling/leakage
AE3D
coatings air flows
AE3D
AE3D P
Power (*) GT
+8 MW AE3D
AE3D
3 Efficiency(*) GT
+1.2pt%
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
g suppliers
pp start

01/10 : Product specification

03/09 : Project Start

Ansaldo Enegia 2010. All rights reserved

Pag. 14
HW5 : Fully 3D Compressor Blades & Vanes

9 Five front stages

g fully
y 3D design
g

9 Completely retrofitable on AE94.2

range gas turbine with same rotor
di k too
disks

9+4% inlet mass flow @same

efficiency

9 Low mass flow variations against

ambient temperature

9 High turndown capabilities

9 Wet
W t compression
i capabilities
biliti

A il 12 : P
April Product
d t commercialization
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%
8.0% increased power output in Combined cycle(**)
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

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

Ansaldo Enegia 2010. All rights reserved

Pag. 17
Summary & Conclusion

Ansaldo Energia Upgrade present and future packages for AE94

AE94.2
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
d HW3 packages).
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
AE94 2 Users Conference
Kuala Lumpur, December 2nd 2010