Steam Turbine - ICCI
Steam Turbine - ICCI
Steam Turbine - ICCI
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YENI ELEKTRIK CCGT 850 MW PROJECT<br />
Authors: Piero Becci and Emrah İpekci<br />
İstanbul, 26 April 2013
Content<br />
1<br />
2<br />
Company and Products Presentation<br />
Project Presentation
Ansaldo Energia group<br />
Come sarà:<br />
ipotesi 1<br />
Ansaldo Energia is a Finmeccanica Group company subject to joint<br />
direction and coordination by Finmeccanica and First Reserve Power.<br />
55% 45%
FINMECCANICA TODAY<br />
Revenues<br />
EUR 3.915 billion<br />
Revenues<br />
EUR 6.035 billion<br />
Revenues<br />
EUR 2.67 billion<br />
Revenues<br />
EUR 1.001<br />
Revenues<br />
EUR 1.223 billion<br />
Revenues<br />
EUR 981 million<br />
Revenues<br />
EUR 1.877 billion<br />
Workforce<br />
13,303<br />
Workforce<br />
27,314<br />
Workforce<br />
11,993<br />
Workforce<br />
4,139<br />
Workforce<br />
4,066<br />
Workforce<br />
1,872<br />
Workforce<br />
6,876<br />
HELICOPTERS<br />
DEFENCE AND<br />
SECURITY<br />
ELECTRONICS<br />
AERONAUTICS<br />
SPACE<br />
DEFENCE<br />
SYSTEMS<br />
ENERGY<br />
TRANSPORTATI<br />
ON<br />
AgustaWestland<br />
DRS Technologies<br />
SELEX Elsag<br />
SELEX Galileo<br />
Alenia Aermacchi<br />
Telespazio (67%)<br />
Thales Alenia<br />
Space (33%)<br />
Oto Melara<br />
WASS<br />
MBDA (25%)<br />
Ansaldo Energia<br />
(55%)<br />
AnsaldoBreda<br />
Ansaldo STS (40%)<br />
BredaMenarinibus<br />
SELEX<br />
Sistemi Integrati<br />
*2011 figures
Ansaldo Energia: Our Mission<br />
Achieve a sustainable growth<br />
by providing a flexible and innovative portfolio of solutions to match<br />
future global energy needs
More than 150 years background<br />
1853<br />
1923<br />
1949<br />
1962<br />
1989<br />
1991<br />
1991<br />
1995<br />
2004<br />
2005<br />
2007<br />
2008<br />
2010<br />
2011<br />
Giovanni Ansaldo & Co. established<br />
First Power Plant<br />
GE license for <strong>Steam</strong> <strong>Turbine</strong>s & Generators<br />
First supercritical 600 MW Power Plant<br />
ABB licence for <strong>Steam</strong> <strong>Turbine</strong>s & Generators<br />
Ansaldo Energia established<br />
Siemens licence for Gas <strong>Turbine</strong>s<br />
First Combined Cycle plant based on Ansaldo Energia GT<br />
New Global Service Strategy<br />
Total technological independence<br />
OSP concept launch<br />
100 th Gas <strong>Turbine</strong> in commercial operation<br />
150 th Gas <strong>Turbine</strong> manufactured<br />
Agreement with First Reserve Corporation
Company Products and Services<br />
Open and Combined<br />
Cycles Power Plants<br />
Thermal Power Plants<br />
Equipment: Gas <strong>Turbine</strong>s,<br />
<strong>Steam</strong> <strong>Turbine</strong>s<br />
and Turbogenerators<br />
Service<br />
on AEN installed fleet<br />
(OEM)<br />
Service<br />
on third party installed fleet<br />
(OSP)
Company Products and Services<br />
Nuclear and Renewables<br />
Engineering and<br />
Construction for New<br />
Nuclear Power Plants<br />
Service on Nuclear<br />
Power Plants<br />
Waste Management and<br />
Decommissioning<br />
Solar PV and Wind:<br />
Turnkey Installations<br />
Biomass and CSP:<br />
System Integrator<br />
Electric Drive System
Financials and Headcount<br />
Orders Breakdown by Business Lines<br />
Renewables<br />
Employees<br />
2006-2011, headcount<br />
Service<br />
New Units<br />
Nuclear<br />
2006<br />
2007<br />
2008<br />
2009<br />
2010<br />
2011
Full Production & Refurbishment Capabilities<br />
Ansaldo Energia<br />
Genoa (Italy) manufacturing plant<br />
Ansaldo Thomassen<br />
Rheden (NL) workshop<br />
Ansaldo Thomassen Gulf<br />
Abu Dhabi (UAE) repair center
Full Engineering Procurement Contractor Capabilities - Full Service<br />
Capabilities<br />
Open Cycle<br />
Combined<br />
Cycle<br />
Thermal<br />
Single<br />
equipment<br />
Engineering<br />
Gas <strong>Turbine</strong>s<br />
Engineering<br />
Gas <strong>Turbine</strong>s<br />
Engineering<br />
<strong>Steam</strong> <strong>Turbine</strong>s<br />
Generators<br />
<strong>Steam</strong> <strong>Turbine</strong>s<br />
Boilers<br />
Contractual<br />
Contractual<br />
Flexibility<br />
BOP and auxiliaries<br />
Civil works<br />
Transportation<br />
Construction<br />
HRSG<br />
Generators<br />
BOP and auxiliaries<br />
Civil works<br />
Generators<br />
BOP and auxiliaries<br />
Civil works<br />
Transportation<br />
Plant commissioning<br />
Transportation<br />
Construction<br />
Construction<br />
Plant commissioning<br />
Turn-Key<br />
plant<br />
Plant commissioning<br />
Life Cycle Service Provider
Certifications<br />
Respecting the<br />
environment<br />
Fulfilling customer<br />
expectations<br />
Releasing quality<br />
products<br />
UNI EN ISO 9001:2008<br />
UNI EN ISO 14001:2004<br />
UNI EN ISO 3834-2<br />
UNI CEI EN ISO/IEC 17025:2005<br />
DPR 34/2000<br />
ANSI/ASME NQA1-2008<br />
IAEA Code N. GS-R-3<br />
ASME Code Symbol N-N-2961; NB
Our Products & Service Lines<br />
Power Plants<br />
Gas <strong>Turbine</strong>s<br />
<strong>Steam</strong> <strong>Turbine</strong>s<br />
Turbogenerators<br />
OEM Services<br />
OSP TM Services<br />
Nuclear Energy & Service<br />
Renewable Energy
Ansaldo Energia Power Plants<br />
Open Cycle<br />
Africa &<br />
Middle East<br />
Installed power<br />
worldwide<br />
about 175,000 MW<br />
in more than 90 Countries<br />
Far East<br />
18%<br />
6%<br />
Hydroelectric<br />
Combined Cycle<br />
Americas<br />
19%<br />
57%<br />
Europe<br />
& CIS<br />
Geothermal<br />
Thermal<br />
Cogeneration<br />
Waste to energy<br />
Solar power<br />
Wind power<br />
References as of December 2011
Gas <strong>Turbine</strong> based power plants<br />
Open Cycle<br />
93 units 13,600 MW<br />
Combined Cycle<br />
85 units 30,100 MW<br />
Customized configuration<br />
High performance<br />
Low environmental impact<br />
References as of December 2011
Gas <strong>Turbine</strong>s portfolio<br />
Model<br />
Power [MW] Class Reliability<br />
AE64.3A<br />
75<br />
F<br />
AE94.2<br />
170<br />
E<br />
> 98%<br />
AE94.2K<br />
170<br />
E<br />
AE94.3A<br />
294<br />
F<br />
Ansaldo Energia<br />
independent technology<br />
Widely<br />
proven<br />
models
Gas <strong>Turbine</strong>s references & performance<br />
Ansaldo Energia Products<br />
87 in Combined Cycle - 88 in Open Cycle<br />
Belgium (1)<br />
France (1)<br />
Germany (3)<br />
Italy (42)<br />
Spain (4)<br />
UK (4)<br />
Algeria (13)<br />
Tunisia (1)<br />
Congo Rep (2)<br />
Ghana (2)<br />
Egypt (7)<br />
Albania (1)<br />
Finland (3)<br />
Greece (3)<br />
Hungary (1)<br />
Poland (2)<br />
Russia (15)<br />
Turkey (2)<br />
UAE (3)<br />
Jordan (2)<br />
Lebanon (2)<br />
Syria (2)<br />
Oman (5)<br />
Other M.E. (44)<br />
Bolivia (2)<br />
Chile (1)<br />
USA (1)<br />
175 Gas <strong>Turbine</strong>s / 30,300 MW sold<br />
Cumulated 7,000,000 EOH<br />
Bangladesh (3)<br />
India (2)<br />
Pakistan (1)<br />
References as of December 2011
<strong>Steam</strong> <strong>Turbine</strong>s Portfolio<br />
Type and application<br />
Series<br />
Reheat <strong>Turbine</strong>s<br />
• Thermal Fossil-fired<br />
<strong>Steam</strong> Cycles<br />
• Combined Cycle<br />
• Cogeneration Plants<br />
• Solar Plants<br />
RT (3 to 5-cylinder) RT30, R70<br />
150<br />
MT-RH (2-cylinder) MT15<br />
90 350<br />
Non-Reheat <strong>Turbine</strong>s<br />
• Thermal Fossil-fired<br />
<strong>Steam</strong> Cycles<br />
• Combined Cycles<br />
• Cogeneration Plants<br />
• Solar Plants<br />
Geothermal <strong>Turbine</strong>s<br />
Geothermal Cycles<br />
MT-TC (2-cylinder) MT20<br />
150<br />
MT-SC (1-cylinder) ): MT10<br />
40 250<br />
GT<br />
20 150<br />
0 100 200<br />
300 1,000<br />
Power Output [MW]
Turbogenerators portfolio & references<br />
Ansaldo Energia started Turbogenerator production in 1920’s.<br />
References since 1950:<br />
Type Unit Power MVA Units<br />
Total Power<br />
MVA<br />
Gas<br />
<strong>Turbine</strong>s<br />
<strong>Steam</strong><br />
<strong>Turbine</strong>s<br />
Air cooled up to 350 516 55, 000<br />
H 2 cooled up to 600 161 25,300<br />
H 2 / H 2 O cooled (2<br />
poles)<br />
H 2 / H 2 O cooled (4<br />
poles)<br />
up to 1,100 58 26,800<br />
up to 1,300 4 4,200<br />
Total 739 111,300<br />
References as of December 2011
Renewable sources types & references<br />
Hydro-electric<br />
530 units - 26,600 MW<br />
Generators for river flow<br />
(low/medium speed)<br />
Geothermal<br />
136 units - 2,300 MW<br />
Power range from 20 to 150 MW<br />
Generators for high-head plants<br />
(medium/high speed)<br />
Motor-Generators for<br />
pumped storage systems<br />
References as of December 2011
Renewable sources types & references<br />
Wind Power<br />
66 MW<br />
Solar Power - Photovoltaic<br />
30 MW<br />
References as of December 2011
Nuclear Portfolio & References<br />
Construction and Services<br />
• Sanmen NPP (China) - AP1000<br />
• Mochovce NPP (Slovakia) – VVER V213-440<br />
• Cernavoda NPP (Romania) – Candu 6<br />
• Embalse NPP (Argentina) – Candu 6<br />
• Krsko NPP (Slovenia) –PWR<br />
• Tianwan NPP (China) – VVER V428-1000<br />
• Chernobyl NPP (Ukraine) - RBMK<br />
• EPC services for nuclear power plants and<br />
research facilities<br />
• Contribution to Generation III+<br />
development<br />
• Contribution to Generation IV development<br />
• Service to operating nuclear power plants<br />
• Decommissioning of nuclear installations<br />
• Radioactive Waste Management<br />
Decommissioning and RadWaste<br />
Management<br />
• Ignalina NPP (Lithuania)<br />
• Trino NPP (Italy)<br />
• Caorso NPP (Italy)<br />
• EUREX Nuclear Facility (Italy)<br />
• Superphénix NPP (France)<br />
• Chernobyl NPP (Ukraine)
Two service families<br />
New Units<br />
Service<br />
Original Equipment<br />
Manufacturer<br />
Gas <strong>Turbine</strong>s, <strong>Steam</strong> <strong>Turbine</strong>s &<br />
Generators<br />
OEM Service<br />
All Ansaldo Energia<br />
products & plants<br />
<br />
SERVICE<br />
on Third party<br />
equipment
Worldwide References<br />
Awarded Capacity Worldwide: 184,300 MW (As of Dec. 2011)<br />
Thermoelectric<br />
Power Plants<br />
138,600 MW<br />
Europe<br />
101,700 MW<br />
Hydroelectric<br />
Power Plants<br />
45,700 MW<br />
Americas<br />
33,900 MW<br />
Africa / Middle East<br />
37,100 MW<br />
Asia / Pacific<br />
11,600 MW<br />
<strong>Steam</strong> <strong>Turbine</strong>s<br />
91,000 MW<br />
Gas <strong>Turbine</strong>s<br />
30,300 MW<br />
Turbogenerators<br />
111,300 MVA<br />
Hydrogenerators<br />
26,600 MVA<br />
References as of December 2011
Ansaldo Energia EPC Contract in the world<br />
Succeeding on the global market as “Turn-key” Power Plant contractor in the last years<br />
2003<br />
ITALY - ROSIGNANO<br />
C.C. 400 MW<br />
2008<br />
FRANCE - BAYET<br />
C.C. 400 MW<br />
2004<br />
ITALY - SPARANISE<br />
C.C. 800 MW<br />
2005<br />
ITALY - LEINÌ<br />
C.C. 400 MW<br />
2010<br />
TUNISIA – SOUSSE<br />
C.C. 440 MW<br />
2005<br />
ITALY - NAPOLI LEVANTE<br />
C.C. Rep. 400 MW<br />
2007 2007 2007 2011 2011<br />
ALGERIA - M'SILA<br />
O.C. 500 MW<br />
ALGERIA - LARBAA<br />
O.C. 600 MW<br />
ALGERIA - BATNA<br />
O.C. 300 MW<br />
ALGERIA – AJN DJASSER II<br />
O.C. 300 MW<br />
ALGERIA - LABREG<br />
O.C. 300 MW<br />
2005 2005 2006 2008 2008 2009<br />
ITALY - MONCALIERI<br />
C.C. Rep. 400 MW<br />
ITALY - VADO LIGURE<br />
C.C. Rep. 800 MW<br />
ITALY - RIZZICONI<br />
C.C. 800 MW<br />
ITALY - TURANO LODIGIANO<br />
C.C. 800 MW<br />
ITALY - SAN SEVERO<br />
C.C. 400 MW<br />
ITALY - APRILIA<br />
C.C. 800 MW<br />
2010<br />
EGYPT - 6 TH OCTOBER<br />
O.C. 600 MW<br />
2011<br />
TURKEY - YENI GEBZE<br />
C.C. 850 MW<br />
References as of December 2011
YENI ELEKTRIK 850 MW CCGT POWER PLANT PROJECT<br />
TURKEY
EPC CONTRACT<br />
Holding full responsibility of<br />
the manufacturing of the main<br />
rotating machinery, design,<br />
purchasing of all plant<br />
components, transport, civil<br />
construction and<br />
electromechanical erection<br />
works, commissioning and<br />
testing of the whole power<br />
plant.<br />
The plant in 2+1 configuration<br />
has a capacity of 850 MWe<br />
using the largest units<br />
produced by Ansaldo Energia.
PROJECT STAKEHOLDERS<br />
YENİ ELEKTRİK ÜRETİM A.Ş.<br />
Owner<br />
UNIT INVESTMENT N.V. (%60) ANSALDO ENERGIA (%40)<br />
EPC Contractor<br />
Consortium of ANSALDO ENERGIA<br />
& YENİ AEN İNŞAAT A.Ş.<br />
Owner’s Engineer<br />
Consortium of TRACTEBEL ENGINEERING<br />
& COYNE ve BELLIER<br />
LTSA Contractor<br />
Consortium of ANSALDO ENERGIA<br />
& YENI AEN İNSAAT A.Ş.
PROJECT LOCATION<br />
The Plant is being constructed within the land allocated to<br />
Kocaeli-Gebze VI - IMES Organized Industrial Zone
GENERAL LAYOUT<br />
GPRS Area<br />
Plant Area
PERFORMANCE<br />
Main Features<br />
• Mainly a Merchant Plant designed for<br />
Heavy Cycling.<br />
• Very Environment Friendly and will<br />
be one of the cleanest power plants<br />
of the category in Turkey. The<br />
environmental parameters shall be<br />
continously monitored to ensure<br />
clean operation at all times.<br />
• Net efficiency LHV, one of the highest<br />
rates of its category.<br />
• PAC after 30 months from NTP
CONTRIBUTION TO NATIONAL ELECTRIC PRODUCTION<br />
Peak Demand<br />
2014<br />
(MW)<br />
Contribution<br />
(%)<br />
2021<br />
(MW)<br />
Contribution<br />
(%)<br />
Low Demand 42.360 2.00 65.440 1.30<br />
High Demand 43.800 1.94 71.985 1.18<br />
Energy Demand<br />
2014<br />
(GWh)<br />
Contribution<br />
(%)<br />
2021<br />
(GWh)<br />
Contribution<br />
(%)<br />
Low Demand 273.900 2.72 424.780 1.75<br />
High Demand 281.850 2.64 467.260 1.60<br />
* Demand values are taken from TEİAŞ 10 Years Production Capacity Projection (2012-2021) December,2012<br />
* Contribution to Energy Demand values are calculated 24 hours, 365 day production.
EPC CONTRACT SCOPE<br />
Engineering<br />
Basic and Detailed Design of Whole Power Plant<br />
Gas <strong>Turbine</strong>s<br />
Manufacturing and Erection<br />
<strong>Steam</strong> <strong>Turbine</strong>s<br />
Manufacturing and Erection<br />
HRSG<br />
Supply and Erection<br />
Generators<br />
BOP and auxiliaries<br />
Manufacturing and Erection<br />
Off-shore and On-shore Procurement and Erection<br />
Civil works<br />
All Permanent and Temporary Works<br />
Transportation<br />
Transportation of all Project Materials<br />
Erection<br />
Commissioning<br />
Erection and Installation of All Systems<br />
Plant Commissioning & Testing
TURBINES & GENERATORS<br />
Gas <strong>Turbine</strong><br />
2 Units - 294 MW<br />
AE94.3A (Class F)<br />
<strong>Steam</strong> <strong>Turbine</strong><br />
1 Unit - 273 MW<br />
RT-30<br />
Generators<br />
2 Units<br />
Model TRY-L56<br />
Generator<br />
1 Unit<br />
Model TRX-L56
MAIN SUPPLY COMPONENTS<br />
2<br />
Heat Recovery <strong>Steam</strong><br />
Generators<br />
1 Air Cooled Condenser<br />
3 Step-up Transformers<br />
1 380 kV GIS Electrical Substation<br />
1 Gas Pressure Reducing Station<br />
+ Auxiliary Systems
ENVIRONMENT - EMISSIONS<br />
AE94.3A<br />
Gas <strong>Turbine</strong><br />
Limit Values<br />
of Turkish<br />
Regulation<br />
NOx [mg/Nm 3 ] < 40 50<br />
CO [mg/Nm 3 ] 30 100
ENVIRONMENT - EFFLUENTS<br />
Operation Discharge<br />
Sanitary Water<br />
Process Neutralized Effluents<br />
All discharges are fully treated for compliance to<br />
discharge open environment according to<br />
Turkish Regulation Water Pollution Control<br />
(SKKY).
EPC CONTRACT DURATION: 30 MONTHS FROM NTP<br />
MILESTONE Date Status<br />
EPC Contract Award November 2010 Completed<br />
Notice to Proceed July 2011 Completed<br />
Start Construction Works 26.07.2011 Completed<br />
Hot-tap Connection to Gas Pipeline 23.12.2011 Completed<br />
Start Mechanical Erection Works 29.04.2012 Completed<br />
Gas<strong>Turbine</strong> 1 Ready at Site<br />
Gas<strong>Turbine</strong> 2 Ready at Site<br />
<strong>Steam</strong> <strong>Turbine</strong> Ready at Site<br />
Gas<strong>Turbine</strong> 1 First Firing<br />
Gas<strong>Turbine</strong> 2 First Firing<br />
<strong>Steam</strong> <strong>Turbine</strong> First Synchro<br />
17.08.2012<br />
19.09.2012<br />
20.09.2012<br />
End of May 2013<br />
Mid-July 2013<br />
Mid-September 2013<br />
Completed<br />
Planned<br />
Project Completion (PAC) January 2014 Planned
HEALTH, SAFETY AND ENVIRONMENT<br />
3.700.000 MANHOURS<br />
WITHOUT L.T.I.<br />
INCIDENT RATE (LTIFR)<br />
Number of Incident per 1 Million Manhours<br />
National 2.46<br />
Project 0.27<br />
PROJECT HAS 9 TIMES<br />
BETTER HSE RECORDS<br />
THAN THE NATIONAL<br />
STATISTICS.
HEALTH, SAFETY AND ENVIRONMENT<br />
TRAINING PROGRESS AT 20th MONTH<br />
HSE<br />
TOTAL<br />
Trained Personnel 7.050<br />
Training Manhours 5.510
HEALTH, SAFETY AND ENVIRONMENT<br />
12<br />
GOLDEN<br />
RULES<br />
PPE Compliance<br />
Smoking Policy<br />
Use of Mobile Phones<br />
Use of ID Badge<br />
Electrical Safety<br />
Driving Safety<br />
Safety Devices<br />
Follow HSE Instructions<br />
Hot Works<br />
Lifting Safety<br />
Work at Height<br />
PTW system<br />
Golden Rules Awarding system for<br />
extensive HSE performances.<br />
Most meritable workers awarded for<br />
demonstration of continuous safe<br />
working practices and became good<br />
example to other employees.
OVERALL PROJECT PROGRESS 90.2% @ MARCH 2013
ENGINEERING<br />
ENGINEERING PROGRESS AT 20th MONTH<br />
ENGINEERING Progress (%)<br />
Civil 100<br />
Electrical 99.7<br />
Plant Engineering 99.6<br />
Automation 99.5<br />
Process 88.3<br />
Total 99.4
PROCUREMENT<br />
PROCUREMENT PROGRESS AT 20th MONTH<br />
TRANSPORTATION<br />
Packages<br />
Transported Weight<br />
(tons)<br />
Off-Shore 752 13.961<br />
On-Shore 1.291 15.787<br />
Total 2.043 29.748
CIVIL WORKS<br />
CIVIL WORKS PROGRESS AT 20th MONTH<br />
CIVIL WORKS Progress (%)<br />
Concrete Casting 99.9<br />
Steel Erection 95.8<br />
Architectural 90.6
MECHANICAL WORKS<br />
MECHANICAL WORKS PROGRESS AT 20th<br />
MONTH<br />
Mechanical Works Progress (%)<br />
Piping (>2”) 94.7<br />
Piping (
ERECTION WORKS<br />
ERECTION WORKS PROGRESS AT 20th<br />
MONTH<br />
Erection Works Progress (%)<br />
Gas <strong>Turbine</strong> 1 100<br />
Gas <strong>Turbine</strong> 2 99<br />
<strong>Steam</strong> <strong>Turbine</strong> 85<br />
HRSG 1 95<br />
HRSG 2 86<br />
Air Cooled Condenser 95<br />
380kV GIS Electrical<br />
Substation<br />
100<br />
Others 91<br />
Total 92.2
ELECTRICAL WORKS<br />
ELECTRICAL WORKS PROGRESS AT 20th MONTH<br />
Electrical Works Progress (%)<br />
Cable Pulling 72.7<br />
Cable Connection 67.4
WEST VIEW
HRSG AND AIR COOLED CONDENSER
GIS SUBSTATION AND ADMINISTRATION BUILDINGS
HRSG AND AIR COOLED CONDENSER
GAS PRESSURE REDUCING STATION
DETAIL OF GAS TURBINE
STEAM TURBINE
STEP-UP TRANSFORMER
GAS TURBINE AND STEAM TURBINE BUILDINGS
CONNECTION TO GRID