University of Genoa

Solutions for Combined Cycle Flexibility

Alessandro Sorce, Phd
4/12/2017

Thermochemical Power Group

DIME – University of Genoa (Italy)
1
tpg.unige.it
 Who is speaking? University of Genoa

• PhD defense on april 2013 on “monitoring and diagnosis of energy Systems”

 Solide Oxide Fuel Cell Diagnosis (Genius Project)
 Internship c/o Power diagnostic Center di Siemens (monitoring of European and Asiatic
CCPP)
• Collaboration with Tirreno Power: Diagnostic Control Room (2013-2014)
 data reconciliation Algorithm: Develop and test
 Focus on special tasks
 Global Monitoring and Report system, GMR

• (2015- present) Large Size Power Plant

 Law for Power Plant management
 Environmental Impact
 Flexible Long term monitoring
 Power plant Flexibility

2
About What?
University of Genoa

1. Large Size Heavy Duty Gas Turbine – O&M Solution

2. HDGT Control Systems:

- Control Loops and typical target
- Methods for Minimum Environmental Load reduction

3. Combined Cycle Management

- Start-up of the Combined Cycle

4. Maintenance cost and the Impact of Flexibilization

5. Monitoring and Diagnosis of CCPP

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 1. Heavy Duty Gas Turbine University of Genoa

Heavy Duty Gas Turbine are exploited in electricity generation tipically

coupled with a Steam Bottoming Cycle as a Combined Cycle
44.0 Increase of Efficiency and power output is due to the higher Turbine Inlet
Temperature reached, combined with higher pressure ratio.
41.8
9HA

510 MW 557 MW

4
 Heavy Duty Gas Turbine Summary University of Genoa

air cooling
closed-loop steam cooling
open-loop air cooling

Turbomachinery International • November/December 2013 S. C. GÜLEN MODERN GAS TURBINE COMBINED CYCLE NET THERMAL EFFICIENCY RATINGS OF 60% ARE HERE —WHAT’S NEXT?

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 Turbogas General Electric 9FA+e University of Genoa

COMPRESSOR BURNERS TURBINE

Pressure Ratio 15,4 N° combustion chambers 18 Expansion stages 3

N° burners for each
Compression stage 18 6 Cooled blades stages 2
chamber
Power absorbed 250 MW Tecnology DLN 2.6+ Cooled vanes stages 3

CTD 390°C

Net Power Output: 261 MW (ISO)

Simple Cycle Efficiency: 37,3 % (ISO)
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6
 Turbogas General Electric 9HA University of Genoa

2015 2017

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7
 Comparison F class vs G class
University of Genoa

Heavy Duty Heavy Duty

GE 9F.05 (2000) GE 9HA.01 (2010)
η 38.2 43.1
β 18.3 (14 stages) 23.5 (14 stages)
T4 (T.O.T) [°C] 640 (3 stages) 629 (4 stages)
T3 (T.I.T) [°C] / eta_t=0.9 1450 1487
Exhaust Energy [MW] 498 588
725.3 872.8
L_s [kJ/kg] 432 511
SC P_el [MW] 314 446
GT turndown MEL [%] 35% 30%
GT Ramp Rate (MW/min) 24(7.6%/min) 65 (14.5%/min)
Startup time [hot,Minutes] 23 23
Nox at Base Load [ppmvd] @15%O2 25 25
CO [ppm] @15%O2 24 8 9
 Turbogas Alstom GT26 – ReHeat (2011) University of Genoa

COMPRESSORE BRUCIATORI EV TURBINA HP

Pressure Ratio 34 N° combustion chambers 24 Expansion Stages 1

BRUCIATORI SEV
Compression Stages 22 TURBINA LP

N° IGV 3 N° combustion chambers 24 Expansion Stages 4

CTD 550°C Gross Power Output 262 MW

Blade Cooling air Temperature Is the only ReHeated HDGT TOT

is reduced via Steam Cooled 650 °C => High Steam Cycle
Heat Exchangers => Close Efficiency
Integration between GT and
Bottoming Cycle
High Turn Down Capability: 20%
with respect to Base Load

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9
 AEN Turbogas GT26 – ReHeat (2016) University of Genoa

Come fa una macchina

ReHeat ad avere un
rendimento maggiore di
quelle in ciclo semplice?

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10
Confronto Ciclo Semplice vs RH
University of Genoa
SC Heavy Duty RH
GE 9F.05 AEN GT26
η [%] 38.2 41
β 18.3 (14 stages) 34 (22 stages)
T4 (T.O.T) [°C] 640 (3 stages) 650 (1+4 stages)
T3 (T.I.T) [°C] / eta_t=0.9 1450 1155/1290
Exhaust Energy [MW] 498 470
725.3 715
L_s [kJ/kg] 432 482
SC P_el [MW] 314 345
GT turndown MEL [%] 35% 10%
GT Ramp Rate (MW/min) 24(7.6%/min) 33 (9.5%/min)
Startup time [hot,Minutes] 23 -
Nox at Base Load [ppmvd] @15%O2 25 <30
CO [ppm] @15%O2 24 <10
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 AEN Turbogas GT36 (2016) University of Genoa

 An H-Class similar to the GE and Siemens

one: Simple Cycle with canned combustion
chambers (with sequential Combustion!!!)
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Turbogas Ansaldo Energia AE94.3 A2 University of Genoa

AE 94.3 A2 (2007)

Potenza netta: 269 MW (ISO)

Rendimento netto in ciclo aperto: 39,6 %
(ISO)
Rapporto di compressione: 17,7 (ISO)
T ingresso Turbina (TIT): 1230 °C
Numero stadi compressore: 15
Numero stadi turbina: 4
Portata metano a MAX carico: ca 19 Nm3/s
Portata dei gas di scarico: 690 kg/s
T gas di scarico (TETC): 570 °C

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Turbogas Ansaldo Energia AE94.3 A University of Genoa

Turbogas AE 94.3 A (2015)

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 Turbogas Siemens 8000H University of Genoa

La prima H- Class
Prodotta (2010)

La più diffusa (80

impianti nel mondo)

Gross Power Output 450 MW

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HCO: Hydraulic Clearance Optimization University of Genoa

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 2. Gas Turbine Control University of Genoa

GT Load Control acts over two main parameters to regulate combustion:

• m_f, fuel mass flow rate => Fuel Control Valves

• m_a, air mass flow rate => HDGT – Inlet Guide Vanes

Two attributes of the Combustion can be regulated:

Quantity (i.e. the amount of energy delivered)
Quality (i.e. the combustion temperature)
m_a TIT

m_f In the operating range, Load control is managed by acting

on both mass flow rates to control Turbine Outlet
Temperature (TOT). In fact even if the firing
TOT
temperature (FT) and the related Turbine Inlet
Temperature (TIT) are more critical with respect to
performance, environmental and high temperature material
issues, the TOT is easier to measure.

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 GT Control: IGV, Inlet Guide Vane University of Genoa

In general for a GT the air mass flow rate is proportional to:

• density (suction temperature and pressure)

• Section flow (Inlet Guide Vanes position)
• Rotational speed

The rotational speed is imposed by the grid, suction

conditions are usually related to ambient conditions:
→ the only way to regulate the mass flow rate is the IGV

Inlet Guide Vanes

There are two extreme position:

IGV Max - fully open
IGV Min - fully closed (bounded by
compressor instability issues)

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 GT Control: IGV e m_fuel University of Genoa

TET = TOT

5. Max Load OTC

Control

1. Start up Phase: GT
reaches full speed no load
(FSNL). Speed Control
2. IGV_min (fully closed), increase of the TOT Temperature with the load. Reduction of the air-fuel ratio
(AFR), Load Control.
3. Regulating IGV, AFR is fairly constant and so TOT, Load Control
4. IGV_max (fully open), a load increase (due to increase of fuel) reduces the AFR increasing TOT, until T
limitation is reached, Load Control.

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 REHEAT GT control: IGV + 2 m_fuel University of Genoa

IGV_min Up to 10% Load, all the fuel is

burned just in the EV (as in simple cycle)
IGV_min over 10% Load The temperatures
at SEV inlet are enough to allow fuel auto- OPC
ignition in SEV

Regulating IGV, temperatures are controlled

to follow a specific OPC (OPerational
Concept)
IGV_max Temperature increases with the
Load
Maximum allowed temperature is related to
the management mode selected for the
machine

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 GT Control in CCPP: Effects over HRSG University of Genoa

HRSG materials limits the maximum TOT

(TOT) ≤ 650 °C
MAX TEMPERAT. HRSG
Reducing the compressor inlet mass flow rate via IGV,
also pressure ratio β is reduced. If the controls is
designed to mantain a fixed TIT (Performance /
Environmental Choice), it results in higher
temperature at turbine outlet.
𝒑𝟑 𝒑𝟑𝒂
𝜷𝟏 = > 𝜷𝟐 = ; TOT=TIT*(1/ 𝜷𝟐 )^(k-1)/k
𝒑𝟒 𝒑𝟒𝒂

Even if it will be possible to reduce further

compressor mass flow rate without instability
issues (stall and surge), the HRSG limit on
temperature will be reached.

Which are the other limit to the TIT variation ?

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TG Controls: effect on emissions University of Genoa

The pollutant emission if a gas fired Turbine and relevant to the local environment are :

Nitrogen Oxide, NOx, a mix of NO ed NO2

which create acid rain and smog int he
atmosphere; Are created by high temperature
combustion, so related to Base Load.

Carbon monoxide (strongly correlated also to

Unburned HydroCarbons, UHC), is caused by
the not complete combustion of the Natural
Gas. Main cause are low temperature and low
residence time in the combustion chamber, it is
mainly related to Low Load.

The residence time usually does not change much on part-load because the
normalized flow approximately remains constant with a variable load

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Flame Type University of Genoa

Emission Limit at Full Load:

Premix Flame (NOx reduction)

Premix Lean Flame Instability (Humming)

Frequency of humming close to structural

frequency (phisical Acceleration)

Limit to the maximum Energy to the

Combustion Chamber

Increasing Premix

Reducing NOx

Increase CC instability

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 TG Control: Burner design -1 University of Genoa

Ansaldo Solution - AE94.3A2 : burners VeLoNOxTM (Very Low NOx)

24 Burners, each burner is divided into 2 burners stage:

- axial (rich combustion)
- diagonal (lean combustion)

R • Up to 60% of GT speed the combustion is

a partly Premixed and the mix is fed by the
m axial burner while trough the diagonal one
p just air is fed;

L • From FSNL both burners are fed with

o premixed air and fuel with different ratio as
a function of the load
d
• The MEL is limited by CO @40% of load

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 TG Control: Burner design -1 University of Genoa

Ansaldo Solution - V94.3A2 : bruciatori VeLoNOx (Very Low NOx)

PILOT PREMIX
Rich, Higher temperatures, Lean, Lower Temperature, less Nox
Annular Chamber stability Production

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 TG Control: Burner design -2 University of Genoa

General Electric solution - 9FA+e: Bruciatori DLN 2.6+

18 burners, each burner is divided into 6 burner stages:

• The 5 external burner stages can manage both diffusion and premix combustion
• The central burner stage is fed just by premixed fuel (PM1)

L • FSNL: central burner in premix while the external burners stage are in diffusion
Fuel nozzle o (high NOx).
a • 20 % load 3 external burners switch to premix mode,
d • 30 % load all in premix mode (MEL). Transition Piece
Forward can

DLN 2.6+ system, with the IBH system allows to

reach a very low TG MEL (70 MW - 26% )

NOx < 30 mg/Nm3

CO < 30 mg/Nm3

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 TG Control: Burner design -3 University of Genoa

Alstom solution : EV + SEV

The EV burner, is a two stages lance
combustor (similar to the Siemens
/Ansaldo one).
The combustion system has more
than 2 free variables

SEV burner is made by a

lance which introduce fuel in
an apt designed Combustion
zone where flue gas from HP
turbine flows. The
combustion is initiated by
the autoignition of the fuel

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 Acoustic instabilities University of Genoa

In lean premixed combustion systems, flows are designed to be turbulent to enhance the mixing of fuel and air. The
turbulence causes a fluctuating heat release resulting in acoustic waves travelling through the combustion chamber, are
reflected at the boundaries, and travel back to the burner. There they tend to influence the flow field and close a thermo-
acoustic feedback cycle, allowing combustion instabilities to develop.

In a lean premixed combustion chamber, there are always some

acoustic instabilities present.
These instabilities are not dangerous during normal operation.
They become dangerous when the amplitude rises too much or
when a dangerous frequency arises in the spectrum (structural
resonance)

Combustion Hummig and Acceleration Monitoring / Analysis => TG Derating or Trip

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Acoustic instabilities University of Genoa

Passive Solutions:
- Humming Frequencyes <> Combustion
Chamber Frequencyes
- Design for low frequency Vortex reduction
- break the symmetry (e.g. CBO)

Active Solutions: to damp

combustion oscillations
every burner was fitted
with a direct drive valve
feed-back controlled by a
pressure measurements J. Hermann, A. Orthmann, Combustion Dynamics: Application
of Active Instability Control to Heavy Duty Gas Turbines

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 Pollutant Control - NOx University of Genoa

Primary measures: For new gas turbines, dry low NOX premix burners (DLN) are BAT. For existing gas turbines, water and
steam injection (1.7 Meuro @140MWth) or conversion to the DLN technique is BAT (2 Meuro @140MWth).

DLN burner

Secondary measures: For most gas turbines and gas engines,

Selective Catalitic Reactor, SCR is also considered to be BAT.
Retrofitting of an SCR system to a CCGT is technically feasible
but is not economically justified for existing plants. This is
because the required space in the HRSG was not foreseen in
the project and is, therefore, not available. The capital costs
of an SCR for gas turbines or internal combustion engines are
in the range of EUR 10 to 50/kW (based on electrical output)
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 Pollutant Control - CO University of Genoa

CO is a pollutant which is created only a part load. The CO limits the turndown capability of a gas based Power Plant =>
Minimum Environmental Load. This aspect become crucial nowadays as a flexibility quality.

Primary measures: reduction in CO formation are achieved by Combustion Optimization (good design of the combustion
equipment, optimisation of the temperature (e.g. efficient mixing of the fuel and combustion air) and residence time in the
combustion zone, and/or use of an advanced control system. Just a cold spot can quench the reaction!

Secondary measures: To reduce the CO emissions, the application of

oxidation catalysts is BAT with the associated emission levels for natural
gas firing mentioned

Calculated reaction time to achieve a CO concentration of 10

ppm in a commercial gas turbine exhaust.
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 Pollutant Control - Limits University of Genoa

As an indication, the yearly average CO emission levels will

generally be as follows for each type of existing combustion
plant operated ≥ 1500 h/yr and for each type of new
combustion plant:

New CCGT of ≥ 50 MWth: < 5–30 mg/Nm3. For plants

with a net electrical efficiency (EE) greater than 55 %, a
correction factor may be applied to the higher end of the
range, corresponding to [higher end] x EE / 55, where EE
is the net electrical energy efficiency of the plant
determined at ISO baseload conditions.
 Existing CCGT of ≥ 50 MWth: < 5–30 mg/Nm3. The
higher end of this range will generally be 50 mg/Nm3 for
plants that operate at low load.

Best Available Techniques (BAT) Reference Document for

Sampling period 1 hour Large Combustion Plants Final Draft (June 2016)

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 Boundary Conditions: Ambient University of Genoa

POWER HR

The main seasonal effect over GT

maximum power production is
related to the ambient temperature.

During summer, the Capacity of a

Combined Cycle can drop of more CfPTamb
than 10% CfCSTamb

ISO
PCC  PCC
ACT
/ CfPTamb ISO
CS CC  CSCC
ACT
 CfCS Tamb
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 Boundary Conditions: Gas quality University of Genoa

Fundamental properties of the fuel

and air/fuel mixture are:
 Heat content
 Flame speed
 Autoignition temperature
 Autoignition delay time
 Flammability limits
 Stoichiometric flame temperature

Typically units are tuned to a specific

heating value and there is a 5%
tolerance on this design value.
However, the rate of change is not
allowed to exceed 0.1%/s. D J Abbott , J P Bowers*, and S R James, THE IMPACT OF NATURAL GAS COMPOSITION
VARIATIONS ON THE OPERATION OF GAS TURBINES FOR POWER GENERATION

For the gas turbine operator, the most likely issues associated with fuel composition variation are
associated with the combustion system in the gas turbine and include:
 high levels of pollutant emissions, especially oxides of nitrogen and carbon monoxide
 component life and integrity issues due to factors such as flame flashback and unstable combustion
 operability issues such as ignition problems and flame failure

[4] Brown M., Bryant N., Haynes D., Study on LNG Quality Issues, a study for the European Commission – 34
JRC Institute for Energy prepared by Advantica Ltd., Loughborough, The UK, April 2008
 Boundary Conditions: Gas quality University of Genoa

higher hydrocarbons are summarized as “C2+”, which is the sum of all mole
fractions of hydrocarbons with more than one C-atom. At the same time
todays gas supplies may carry a large and varying content of inert gases,
mainly CO2 and some N2

The higher hydrocarbons typically increase the reactivity of the fuel-air

mixture which lead to increased flammability limits (often advantageous)
and higher flame propagation speed cases lead to flame flashback and
combustor hardware damage.

Riccius, Smith, Guthe, Flohr, THE GT24/26 COMBUSTION TECHNOLOGY AND HIGH HYDROCARBON (“C2+”) FUELS, GT2005-68799 35
CCPP – Performance evolution (design) University of Genoa

64% in Ciclo Combinato

Why 50 Hz Machine produces approx. 40% more power than the 60 Hz ones
equipped with the same technology?
Rotational force depend on squared rotational speed => 3600^2/3000^2=1.44
60 Hz machine size must be ca 40% smaller than the 50 Hz
36
 CCPP – Performance evolution University of Genoa

These operating efficiencies are yearly averages 60

and cover the full range of different situations
that may affect efficiency, e.g. different load 55
modes and factors, different cooling systems,

LHV Efficiency [%]

different ages or climatic conditions 50

45

40

35

30
2003 2005 2007 2009 2011 2013 2015
I - CCPP [18] UK - CCPP [19] UK+IE - NGPP [20]
D - NGPP [20] FR - NGPP [20] DK+FI+SE -NGPP [20]

[18]AEEGSI, Relazione 24 Giugno 2016, 339/2016/l/efr; http://www.autorita.energia.it/it/docs/16/339-16.htm

[19]Departement of Energy & Climate Change, DIGEST OF UNITED KINGDOM ENERGY STATISTICS 2015
[20]Ecofys, International comparison of fossil power efficiency and CO2 intensity - Update 2014 Final Report
LCP BREF, DRAFT 06 2016
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 Boundary Conditions:Electrical Market University of Genoa

Power market evolution is heavily impacting

thermal generation: load factor reduction, number of
start up increase, with a direct effect on the profitability
of these Assets, often leading to mothballing or closure
of these plants. Some Gas Assets will be able to
survive via more flexibility : in terms of minimum
load, ramp rates, start up time… which can lead to
ancillary services revenues. Gas units needed for the
security of the system will require the introduction of a
sustainable capacity remuneration mechanism.

Wim Broos
SVP Thermal Fleet Management

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 380 MW CCPP: Operating Data University of Genoa

Flexibility operation data 2009 - 2013

Start up [n°] Operating hours [h] Poly. (Operating hours [h])
180 9.000
168
160 152 8.000

140 7.000
121
120 115 6.000
5.973

Operating hours [h]

Start-up [n°]

100 91 5.000

80 4.000
3.651

60 3.000

40 2.827 2.000

1.562

1.511
20 1.000

0 0
2009 2010 2011 2012 2013
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 Ancillary Services – MSD
University of Genoa

UCTE Handbook: “Ancillary services” are all services which support elementary functions of electric power system and
they are supplied by subjects dealing of production, control and transmission of electric power.
Ancillary Services are:
• frequency control;

• reactive power and voltage control;

Part of those services are mandatory, other are offered on a special market (Mercato dei
Servizi di Dispacciamento, MSD), where Active power is «payd as bid», on the base of
the TSO (Transmission System Operator) indications.
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Flexibility: Solution for CCPP University of Genoa

41
 Reduce Minimum Environmental Load University of Genoa

To compete on the electricity market an high

: turn down capability is mandatory
(T.D. < 40% B.L.), the limit is related to Gas Turbine to maintain a minimum fuel/air ratio avoiding CO
production.
The Minimum Environmental Load, for the gas turbine is tipically located close to the IGV full closed position,
minimum air mass flow rate.

GT solutions to reduce the air taking part to combustion:

• IGV extra closure
• Compressor recirculation (Inlet bleed heating – anti icing)
• Reduction of compressor inlet density (inlet heating)
• Optimized burner design (staged combustion)
• Combustion chamber by-pass (through Blow-off / cooling air valves)

other solutions:
• CO Catalyst
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 Minimizing the MEL: IGV position University of Genoa

IGV Extra Closure

Through the IGV extra closure it’s possible to reduce the minimum air mass flow rate to the combustion
chamber resulting in higher combustion temperatures at lower load, avoiding CO formation.

CO after CO
TETC = TOT

before

Power reduction Impact on Efficiency

-11% - 2.5%

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 Minimizing the MEL: By-passing Burner University of Genoa

Blow-off Valves

Cooling Valves

An optimization of the minimum load performance can be obtained by reducing the mass flow rate entering the
combustion chamber through:
- Regulating Blow-off valves: discharging mass flow directly to the HRSG diffusor (MEL -12%)
- Regulating Cooling valves: increasing the air mass flow rate fed to cool the 2° and 3° vanes (MEL -4%)

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 Low MEL: Recirculating compressor University of Genoa

GE solution: IBH Valves, Inlet Bleed Heating

A mass flow rate up to 5% of the air is recirculated to the

compressor inlet to:
• Avoid Ice formation when the inlet temperature is very low
• Control the surge margin
• Extend premix combustion to lower load

Power reduction Impact on Efficiency

-22% -10%

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Low MEL: Recirculating compressor University of Genoa

Compressor discharge mass flow recirculation

The Inlet Bleed Heating (IBH) reduce the mass flow rate of the air entering the combustion
chamber thanks to:
- direct effect, the spilled mass flow rate (-5%)
- indirect effect, the decrease of the air density at compressor inlet (-7%) .
Hp: Turbine Inlet Temperature constant (air/fuel ratio constant)
IBH CLOSED IBH OPEN
(5% recirculated mass flow)
Air to the compressor % 100% 93% (+20°C CIT)
Compression Power MW 120 117
Flows to the burners % 100% 88%
Espansion Power MW 240 211
GT Net Power MW 120 94 (-22%)
GT Fuel Power % 100% 85% (+20°C CDT)
GT efficiency % 28 % 25 % (-10%)

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 Inlet Heating:
MEL reduction and part load efficiency University of Genoa

An optimization of the part load performance can be obtained increasing the inlet temperature by the means of
an heat exchanger. The effect is the reduction of the off-design condition (higher efficiency) during part load,
while maintaining the same power production. Moreover this solution help to decrease the MEL.
This upgrade requires the installation of and air water Heat exchanger in the filter house resulting in an
addictional pressure drops at GT inlet

2
1,8
GT inlet
Impact on efficiency [%]

1,6
1,4 temperature
1,2
1
0,8
0,6
0,4
0,2
0
0,4 0,5 0,6 0,7 0,8 0,9 1
Load / Base Load ISO
20°C (+5°C) 25°C (+10°C) 30°C(+15°C) 35°C (+20°C)

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TG Control: Burner design University of Genoa

Shutting Down SEV Alstom Based –

Combined Cycle can reach a Very
Low Load (20% ca), no Reheat Cycle

Combustors are gradually shut-down, which can

lead to not uniform discharge temperature
distribution

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 Minimizing the MEL: CO catalyst University of Genoa

Flue gas post processing:

A grid composed by platinum to be introduced in HRSG, oxidizes CO to CO2 with an efficiency higher than 95%

The CO catalyst allows the reduction of the MEL of 25% without additional
impact over the GT off-design

The positive effect over the CO emission can be exploited to reduce TIT on all
that condition in which performance is not critical, reducing the High
Temperature Degradation Effect over the Expander

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Case Study: flexibility in the electrical market:
start up cost Vs production revenues University of Genoa

Typical Price Profile of the Day Ahead Italian market

Daily Cycling is
mandatory
50
 Case Study: flexibility in the electrical market:
start up cost vs production revenues (Base Load) University of Genoa

CCPP #1 CCPP #2 CCPP #3

Gas cost during Start up euro 12000 8000 6500
Energy produced during start-up MWh 50 40 30
Power Base Load MW 385 385 385
eta base load % 56 56 56
Specific cost Base Load euro/MWh 59.1 59.1 59.1

CCPP#3: 2 start-up / day

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 Case Study: flexibility in the electrical market:
start up cost vs production revenues (Base Load) University of Genoa

CCPP #3 CCPP #3 MEL CCPP #3 Pmax

Gas cost during Start up euro 6500 6500 6500
Energy produced during start-up MWh 30 30 30
Power Base Load MW 385 385 420
MEL MW 175 140 175

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 4. Combined Cycle Management University of Genoa

Combined Cycle Power Plant management have to take into

account:
 the market price of the electricity
 the variability of the fuel cost,
 the cost of start-up maneuver
 the cost of maintenance
Main interest on:
In particular nowadays, in Europe: - Reduction of time and costs
 More Renewables drives the need for CCPP flexibility
of the plant start-up
- Evaluation of the cycling
 CCPP’s have to change load faster
impact (maintenance costs)
 Daily start-up and even double daily start-ups - Extended long term
 Faster Start -up times Required monitoring condition
53
 CCPP start-up
University of Genoa

Start up maneuvers affects thick components which operates at

high temperature, due to thermo-mechanic fatigue, mainly:
- Steam Turbine Rotor - High Pressure Drum
The are systems which cap the run up velocity to avoid
exceeding the “permissible” thermal stress:
- Rotor Stress Evaluator - Boiler Stress Evaluator

54
Start-up Efficiency Impact University of Genoa

• The primary energy burnt during an

average start-up is ca 1900000 MJ
(48300 Sm3 di gas) with an electrical
production of 185 MWh
• This electrical production has quite no
impact with respect to economical gain
• During a typical daily 15 h Load
profile, 4775 MWh are produced with
an average gas consumption of
31.500.000 MJ. CSN = 6583 kJ/KWh
(eta=54.7)
• Taking into account the start-up the
CSN rise up to 6714 kJ/kWh (eta=53.6)

Taking into account the start-up, the efficiency drops from 54.7 to 53.6

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 Combined Cycle Start-up Potential Saving University of Genoa

FSNL Potential to save time by:

1.Decrease/cancel HRSG purging time
4 2.Increase HRSG pressurization ramp rate
1 2 3.Anticipating steam turbine start-up
5 4.Increasing steam turbine ramp up rate
3
5.GT load strategy: increase load as quick as possible
to reach quicker Pmin (context of tertiary reserve)
Potential to save fuel by:
1.Keeping installation as hot as possible during
shutdown
2.Decreasing/cancelling HRSG purging time
3.Increasing HRSG pressurization ramp rate
4.Anticipating steam turbine start-up
1) HRSG Purge (Blow off open –Electrical Drive) 5.Increasing steam turbine start-up ramp up rate
2) Ligth on 6.GT load st-up strategy: wait for steam turbine start-
3) GT speed Ramp (Blow off open – Mixed Gas/Electrical Drive) up before to increase the GT load
4) Syncronization (Blow-off Closed – Gas Drive)
5) GT Load Ramp
56
 Purge Time Reduction University of Genoa
Two Standards Apply:
- API 616 Gas Turbines for the Petroleum, Chemical, and Gas Industry Services
Purge 3 - 5 the volume of the exhaust system (generic)
- NFPA 85 (National Fire Protection Association) Boiler and Combustion Systems Hazards Code
(Specific for the HRSG) Purge prior to the lightoff of the combustion turbine shall be accomplished by at
least five volume changes and for a duration of not less than 5 minutes.
This volume shall be calculated based on the following:
(1) The combustion turbine operating at full load with no supplementary HRSG firing
(2) The volume from the combustion turbine inlet to the portion of the HRSG or other combustion turbine exhaust systems where the
combustion turbine exhaust gas temperature is reduced to at least 56°C (100°F) below the lowest autoignition temperature of the fuel(s)
for which the system has been designed
In no case shall the volume in 8.8.4.2.1.2(2) be less than the volume of the HRSG enclosure between the combustion turbine outlet and
the outlet of the first evaporator section in the HRSG.
API 616 NFPA85
HRSG + Camino HRSG + Camino Fino a EVA AP Purge Credit is
Purge Volume m3 8400 8400 3280 another HW/SW
portata d'aria m3/s 41.5 41.5 41.5 option to skip
n. ricambio volumi # 3 5 5 purge time
tempo PURGE min 10.1 16.9 6.6
57
 St-Up: FSNL Behaviour University of Genoa

Minimo Tecnico
Gradiente di Tempo per il
Carico TG massimo Gruppo TG1 (MW) TG2 (MW) TV (MW) CCGT (MW)
(MW/min) carico (min) GE in 1+1 70 - 72 142
GE in 2+1 70 70 140 280
AEN 6.5 -13 40 - 20 AEN in 1+1 146 - 70 216
AEN in 2+1 146 146 150 442
GE 20 13

58
 GT behaviour impact over Start-up Costs University of Genoa

exhaust temperature @ partial load

 Higher exhaust temperature at FSNL/lower load HRSG pressurization with lower gas consumption
speed up and load up gradients

Cost [euro/MWh]
 reduce start up time and cost

Electricity
Start up cost of 2 different 10000
Units: UNIT 1

Start-up Cost [euro]

8000
• Unit 1 gas turbine TETC UNIT 2
480°C @FSNL 6000
• Unit 2 gas turbine TETC 4000
480°C@80MW
2000

0
0 20 40 60 80
Electricity price [euro/MWh]
59
St-Up: 2+1 AEN/Siemens (Hot Pressurized) University of Genoa

HRSG FLAME ON FLAME ON Minimo Full load

PURGING TG1 TG2 tecnico

Total Time= 65 minutes

60
St-Up: 2+1 GE (Warm) University of Genoa

HRSG Minimo
PURGING FLAME ON tecnico

Tempo complessivo= 85 minuti

61
 GT Control: IGV e m_fuel – OPFLex VLP University of Genoa

Allows independent control of load and exhaust temperature within

the gas turbine boundaries … true GT flexibility product
• Simple interfaces for integrating into existing plant operation
• Requires OpFlex AutoTune to manage combustor operability

Temperature matching with the bottoming Cycle Stand Still Temperature

Dr. Artur Ulbrich, Andy Jones, Christian Schäferkordt, Stuart Simpson, Increasing 62
competitiveness of CCGT plants in a dynamic market: An owner´s approach
 GT Control: IGV e m_fuel – OPFLex VLP University of Genoa

Dr. Artur Ulbrich, Andy Jones, Christian Schäferkordt, Stuart Simpson, Increasing 63
competitiveness of CCGT plants in a dynamic market: An owner´s approach
 GT Control: IGV e m_fuel – OPFLex VLP University of Genoa

Dr. Artur Ulbrich, Andy Jones, Christian Schäferkordt, Stuart Simpson, Increasing 64
competitiveness of CCGT plants in a dynamic market: An owner´s approach
 St-Up: Bottoming Cycle Limitations University of Genoa

BSE compliant Pressure Ramps

120

HP DRUM Pressure [bar]

Pressurization gradient for Drum-type HRSG 100
Minimum HP
80

 6/8 °C of Tsat/min, to be monitored with BSE (Boiler

ST pressure
60

Stress Evaluator) 40

20

0
0 10 20 30
minutes50
40 60 70 80 90
Length of main steam piping P Drum HP ini 0 bar
P Drum HP ini 12 bar
P Drum HP ini 6 bar
P Drum HP ini 20 bar

 Important design impact – length between bypass

and ST

Drains design
 Drains review to reduce the main steam piping
warming time
Once trough Benson Boiler, is an option for start
up not constrained by the Drum thickness

65
 Reduce cost of Start-up: ST characteristic University of Genoa

Speed up available @ lower pressure

 Steam Turbine with direct connection from the HP/IP body to condenser during start up
allow a wide range of speed up pressure (anti-Ventilation Valve).
Lower weight of the rotor
 Impulse design steam turbine allows faster load up due to lower rotor weight and
dimension.

66
 St-Up: Bottoming Cycle Initial Conditions University of Genoa

Start up are classified on the base of the initial conditions of the bottoming Cycle when the
start up maneuver is initiated:
• Steam Turbine Metal Temperature ( Rotor centre or first vane); GT flue Gs Temperature
• High Pressure Drum Pressure
HP Drum T Rotor Gradiente giri TV Full Speed time Main Steam Steam Temperature
Start –Up Type Stand Still (h)
Pressure (bar) Centre(°C) (rpm/min) (min)
Cold t>64 p<2 < 150 75 40 ST Metal Temperature
Warm 16<t<64 p<12 150 < T < 370 150 20
Hot t<16 p<12 T > 370 300 10
Temperature Mismatch < 50
K (stress reduction)
Hot pressurized t<16 p>12 T > 370 300 10

Some times to avoid cold start up conditions (below the

ductile to brittle transition temperature) auxiliary steam is
used to mantain the rotor in warm conditions

To mantain HRSG temperature, the flue gas stack damper is

close after shut down.

67
St-Up: Bottoming Cycle Initial Conditions University of Genoa

68
 Rotor Stress Evaluator (RSE) University of Genoa

The Rotor Stress Evaluator (RSE) is the system which

limits the gradient of ST and GT load in order to reduce
the fatigue on the components
1. Basing on temperature measurement representative
of the rotor surface (Starting Probe), Temperature
distribution is calculated
2. If Relative Comparative stress exceed a threshold, a
load reduction is triggered for the GT.

-RSE give no information about start up impact on the

residual steam turbine life (Damage Calculation),
-the definition of “Permissible” is not clear

69
 Stress Evaluation and Low Cycle Fatigue University of Genoa

The stresses in the rotor are produced by:

- temperature gradients in the material (Thermal
Stress),
- the centrifugal force,
- the pressure.
Thermal Stress
the main contributor: about the 95% of the overall
stress during start up transient

70
Warm Start-up (T_initial =345°C ) University of Genoa
600 600
500 500
400 400
TEMPERATURE [°C]

POWER [MW]
300 300
200 200
100 100
0 0
0 100 200 300 400 500 600 700
TIME [min]
Surface Temperature Mean Temperature Center Temperature
Turbogas Power Steam Turbine Power

100

0
0 100 200 300 400 500 600 700
STRESS [MPa]

-100
Radial Stress
-200 Circumferential Stress
Axial Stress
-300

-400
TIME [min]
71
 Warm Start-up (T_initial =345°C ) University of Genoa

400

300
STRESS [MPa]

200 Surface
Center
100

0
0 100 200 300 400 500 600 700
TIME [min]

- During the shut down thermal stress not exceed 40 Mpa

- Considering as fatiguing cycle the stresses caused by start up and shut down, a fully-reversed loading condition is not
got. Therefore it is possible to consider a zero-max-zero profile loading condition and neglect shut down impact over LCF

Start Up Downtime Initial Rotor Mean Gradient Temperature Maximum Specific Life
[h] Temperature [°C/h ] Variation Number of Consumption
[°C ] [°C ] Cycles [%]

Warm 40 345 255 170 3300 0.03

72
 CLE Curves – HP Rotor University of Genoa

CLE= f(total range of Temp [°C]; Temp gradient [°C/h])

such curves allows to:

knowing in advance the reduction of
turbine's life connected to a given
maneuver or gradient of temperature
change
making choices on the reduction of
warm up and load times, and then on
the increase of temperature gradients
that the rotor will have to endure
choosing whether to sacrifice some of
the useful life of the rotor to gain
greater operating flexibility

73
Curve CLE – HP Rotor University of Genoa

WARM COLD
40 h SS 144 h SS
Ti = 345 °C Ti = 150 °C
N = 3300 N = 600

COLD
HOT 240 h SS
18 h SS Ti = 90 °C
Ti = 394 °C N = 600
N = 14000

HOT
6 h SS
Ti = 450 °C
N > 100000
74
ST Yearly Life Consumption Estimation University of Genoa

Basing on operating conditione the average yearly start-up related life consumption
was evaluated

Miner-Robinson rule was use to combine LCF Life Expenditure and creep effect due to
high temperature normal operation (creep-rupture life 300,000 h ).

low cycle fatigue a yearly consumption 5.05% (as in table 4)

Creep yearly Life Consumption 1% (3000 Operating Hours /Year)
Total Yearly Life Consumption 6.05%

17 years until defects nucleation

75
 Maintenance Cost in CCPP University of Genoa

The LTSA, Long Term Service Agreement, offers to the power plant owner a series of planned maintenance outages.
700
Interval between outages is defined on the base of the operating duty of the machine (load profile)
600
FH/avv_lim=31.7
500

400 6h/d 10h/d

STARTS
Starts

14h/d
300

TGB
200
TGA
TGC
100 24h 5/7 Weekly
24h 2/7 Quarterly Montlhy
0
Fired Hours 0 5000 10000 15000 20000 25000 30000
EQUIVALENT OPERATIVE HOURS
Usually Equivalent Operative Hours,EOH , are use to taking into Profili di carico Cycling Limit Limiti per la manutenzione

account the impact of start-up (1 start- up = 10 Fired Hours) and
this was used to evaluate maintenance costs over the Maintence
Interval (e.g. 25000 EOH) (hourly cost approach) (ca 180eur/h).
Nowadays the maintence limit is reached on the
maximum number of starts, so if the machine is operated
for less than 31.7 hours per start-up the maintence cost
related increases (tipically up to 6000 eur )
76
 Major Factors Influencing GT Maintenance University of Genoa

Gas Turbine Hot Part, and in particular Blades and

Vanes, as function of operative conditions, are
affected by several wear mechanisms.

Daily operational profile reduce the number of fired hours

for maintenance interval (from 23500 to 4100) and so the
time for Power Production => Maintenance Cost per
hours increase of a factor 5.7

Cicle to end life

Average Fired Critical Damaga Oss.
Operational Profile Hours (h) Mechanism Fired Hours to end life Fatica Creep Ciclica
Quarterly 2160 Oss Ciclica 23500 129 62 11
Monthly 720 Oss Ciclica 23500 163 183 30
Weekly 92 Fatica e Oss Ciclica 23500 255 1462 261
Daily 10 Fatica 4100 414 13500 2400

C. Rinaldi, V. Bicego, P.P Colombo, Rapporto CESI, Aprile 2004

Heavy-Duty Gas Turbine Operating and Maintenance Considerations GER-3620M (02/15) 77
 Maintenance Interval University of Genoa

Different methodology to take into account the impact of Operational life

to evaluate the Maintenance Interval :
• Opzione A: Numbers of start-up and fired hours (FH) are not correlated,
each one has its own threshold which triggers the Maintenance, (General
Electric approach);
• Opzione B: Each start up cycle –or fast transient event- is counted with
a number of Equivalent Operative Hours (EOH), the sum of the total EOH
depends liearly from both FH and start up numbers; (Ansaldo, Siemens,
Alstom approach)
• Opzione C: A more complex correlation is used (Alstom Approach)
What are Operative Equivalent Hours (EOH)?
Cyclic thermal stress due to start up and fast transient are taken into account by and equivalent amount of
Equivalent Operative Hours (=> EOH)
Under normal condition 1 Fired Hours is equivalent to 1 EOH.
This value is modified if aggresive fuel, higher flame temperature than standard is used.

B method will be used for following consoderationsconsiderting each start up maneuver

equal to 10 EOH and each FH queal to 1 EOH. A limit to a maximum 600 start ups is added
78
 Ex: Maintenance Costs University of Genoa

Outages Interval [EOH]

 Running Inspection
Minor 4000
 Standby Inspection
 Scheduled Maintenance HGPI 25000
Major 50000

Maintenance Costs € Maintenance Thresholds

700
HGPI Costs 4500000
600
HGPI Interval 250000 EOH 500

Num. Of Start-up
EOH / Start Up 10 EOH 400

Hourly Maintenance Cost (eur/EOH) 180 300

Expected cost/St-up 1800 200

Numbers of start up maintenance Thrshld 600 100

0
0 5000 10000 15000 20000 25000 30000
FH

79
 Comparison of Operational Profiles University of Genoa

Operational Profiles Yearly operation Hours Yearly start-up

Yearly Operational Profile
6h/d 2106 350 700
10h/d 3538 353 FH/avv_lim=31.7
14h/d 4981 355 600

24h 2/7 2309 48

500
24h 5/7 6051 50
Weekly 8551 50 10h/d
400 6h/d
Monthly 8541 11
Quarterly 8539 3 14h/d
300

TGB
200
Operational Maintenance Interval TGA
Profiles FH/avv EOH / MI FH / MI TGC
100 Weekly
6 h/d 6 9600 3600 24h 2/7 24h 5/7
10 h/d 10 12000 6000 Quarterly Monthly
0
14 h/d 14 14400 8400 0 5000 10000 15000 20000 25000 30000
Profili di carico Cycling Limit Limiti per la manutenzione
24 h 2/7 48 25000 20690
24 h 5/7 120 25000 23077
Weekly 168 25000 23596 • 11,44 h for TGA;
Monthly 730 25000 24662
average FH / avv: • 10.29 h for TGB;
Quarterly 2182 25000 24886 • 9.4 h for TGC.
80
5. On line Performance Monitoring University of Genoa

81
FLEXIBILITY – Process Control University of Genoa

82
 Flexible Monitoring of CCPP
University of Genoa

The first rule of monitoring is: ℎ −ℎ

«make them comparable» TG: compressor efficiency ℎ = 𝑓 𝑈𝑅, 𝑡 η =
_
𝑻𝑮
ℎ −ℎ
Several filter strategies are usually Train
adopted: Steady state, full load,
active auxiliaries

Test

Nowadays Full load operation covers just a

fraction of a CCPP life (Load Factor around 60%) Such approach is applied to all
To increase the range of the monitoring results An Hybrid, knowledge based and Data those components which have
base lines are now created taking into account Driven model are the used to create a broad working range
not just the full load conditions reference base line
83
 PCR: Big Data for monitoring University of Genoa

Principal Component Regression (PCR) Multicollinearity

• Multiple Linear Regression (MLR) technique that is based on •
Principal Component Analysis (PCA)
• Method to model a response variable when there are a large •
number of predictor variables which are highly correlated
(multicollinearity)
Multicollinearity is a phenomenon in which two or more predictor
variables in a multiple regression model are highly correlated
A principal danger of such issue is that of overfitting in regression
analysis models

PCR can overcome the multicollinearity issue

• PCR can deal with it by excluding the less important principal components in the regression step
• Dimension reduction by lowering the effective number of parameters characterizing the underlying model

5/13
 NOX – Abnormal behaviour University of Genoa

NOX Abnormal behavior due to Detected fault

burners fouling: 22th November
• Presence of early warning Early warning
alarms 8th August
• Offset in the response variable
reconstruction

First warning alarm one month before

the detected fault
Francesco Fanciulli - Gas turbine monitoring and
predictive diagnostic by means of Knowledge Discovery
in Databases (KDD) techniques
 Final Summary
University of Genoa

1. Large Size Heavy Duty Gas Turbine

2. HDGT Control Systems:

- Control Loops and typical target
- Methods for Minimum Environmental Load reduction

3. Combined Cycle Management

- Start-up of the Combined Cycle

4. Maintenance cost and the Impact of Flexibilization

5. Monitoring and Diagnosis of CCPP

86
 Proposte di Tesi
University of Genoa

1. Metodi diagnostici data-driven di impianti per l'energia (collaborazione Ansaldo Energia)

2. Flessibilizzazione di impianti TG - Metodi per la riduzione e costo del Minimo Tecnico

3. Analisi e modellizzazione del sistema energetico italiano e applicazione a scenari energetici

futuri

4. Integrazione di accumuli termici in impianti termoelettrici di grossa taglia (PUMPHEAT) in

collaborazione con IREN

5. Analisi tecno-economica dei Sistemi di Accumulo Elettrici e Termici per la gestione della rete
elettrici

Proposte da parte vostra?

87