FLEXTURBINE Public Workshop with Policy Makers March, 9 th 2017, 13:00-18:00 CEST Presentation of first FLEXTURBINE results (Luboš Prchlík DSPW)

Transcription

1 FLEXTURBINE Public Workshop with Policy Makers March, 9 th 2017, 13:00-18:00 CEST Presentation of first FLEXTURBINE results (Luboš Prchlík DSPW) Flexible Fossil Power Plants for the Future Energy Market through new and advanced Turbine Technologies

2 FLEXTURBINE FLEXible TURBOmachinery H2020 LCE Highly flexible and efficient fossil fuel power plants Grant agreement reference: FLEXTURBINE Project duration: 36 months, January 2016 December 2018 Budget: Partners: Coordinator: 9.5 Mio (EC funding 6.5 Mio ) 21 partners from 7 countries Doosan Škoda Power Luboš Prchlík, Ph.D. Doosan Škoda Power Tylova 1/ Plzen, Czech Republic Tel.: lubos.prchlik@doosan.com Project web site: 2

3 FLEXTURBINE Mission Project aims to strongly advance state-of-the-art fossil fuel power plant engine technology Major challenges Stability - stable energy grid is one of the major prerequisites for a prosperous European economy Flexibility - the future electricity networks will have to cope with a range of uncertainties related to both the supply of energy from wind, solar, biofuels and fossil fuels and also varying demand Efficiency - environmental, in terms of minimizing and reducing CO 2, NO x, and other greenhouse gases emissions, and also economical, in terms of the cost and affordability of electricity Specific requirements Safe permanent operation at minimal load High number of start-ups, short start-up times High efficiency at partial loads Lifetime extension (retrofitting the existing fleet) Maintenance scheduling longer service intervals Reduced maintenance costs 3

4 FLEXTURBINE Limiting technology for flexible operation Focus on key areas limiting ST and GT flexibility Flutter - Aero-elastic instability - Potential immediate blade destruction - Limitations on partial and off-design operation - Limitations on minimal load operation FLEXIBLE TURBO- MACHINERY Seals and Bearings - Increased wear due to flexible operation - Consequent undesirable leakage flow - Mechanical losses of bearings reduced efficiency - Rotor-stability concerns for low clearances Life Cycle Management - Increased thermo-mechanical loading due to flexible operation - Limitations on number of start-ups - Limitations on start-up times - Lifetime restrictions - Maintenance scheduling shorter service intervals 4

5 FLEXTURBINE The Consortium 21 partners from 7 countries 7 Industrial partners 12 Academic partners 2 SMEs 5

6 FLEXTURBINE Key technologies of interest 6

7 FLEXTURBINE Project Structure WP1 Whole engine modelling and assessment Defines requirements using power plant models Tracks progress of new technology from WP developments and consults with UCG Determines the whole engine flexibility impact WP2 Flutter-resistant turbine blade design Investigates the phenomena and mitigates the risks of consequent hardware faults. WP3 Seal and bearing design Optimizes the sealing and bearing systems of GT and ST for flexible operation WP4 Life cycle management Develops improved fatigue lifetime methods for flexible operation WP5 Management and sustainable impact Technical coordination and project management IPR, dissemination and exploitation management UCG - User Consultation Group TSOs and PPOs provide feedback on the newly developed technology and development plans Eurelectric, EirGrid, ČEZ, ČEPS, VGB Group 7

8 Requirements for development Results, gains Requirements for development Results, gains Requirements for development Results, gains Achievements WP1 Whole engine modelling and assessment Requirements EU targets and call objectives WP1 Activities Capture flexibility requirements Power plant simulation Performance and economics impact of flexibility gains WP2 Flutter WP3 Seals and Bearing WP4 Life Cycle Management Literature data WP leader: Trevor Kirsten 8

9 WP2 Flutter resistant turbine blade design Stable base load operation Cycling backup power Flexible operation Low-load operation Off-design operation STABLE Large last stage ST blades UNSTABLE- Flutter Flexible operation leads to much more complex flow structures where the numerical prediction capabilities are still insufficiently accurate Flutter is the aero-elastic phenomenon that may lead to immediate destruction of the blade Objectives - to develop CFD design tools for flutter prediction validated by experimental testing in order to design flutter resistant blade State-of-the-Art Low capabilities of SW predictive tools Limitations on minimum load Limitations on condenser backpressure Innovation beyond the State-of-the-Art CFD predictive tools Flutter resistant last stage ST blade No limitations on minimal load Less restrictive limit on backpressure TRL 3-6 9

10 M15 M36 CFD simulations Wind tunnel testing Manufacturing of test turbine M1 M15 Development of flutter-resistant blade Design of T10MW test turbine Steam testing of the newly developed LSB WP2 Flutter resistant turbine blade design Calibration Prediction Wind tunnel cascade T10MW test steam turbine Complex tool for flutter prediction Validation WP leader: Mauro Maccio 10

11 WP3 Seals and bearings designs Seals - deterioration over time, seal clearance and, hence, amount of undesirable leakage flows increases due to rub and wear, progressively reducing the efficiency of the plant and increasing emissions Bearings - due to tight clearance and low damping in bearings the instability of the turbine rotor due to self-excitation may occur Objectives - To optimize the sealing and bearing system of gas- and steam turbines for flexible operation (cyclic load, fast ramp-up rates) with regard to performance, availability and increased component lifetime State-of-the-Art Fast and frequent load cycles contribute to seals deterioration undesirable leakage flows reducing the efficiency, increasing emissions Tight bearing clearances and low bearing damping may lead to rotor instability due to self-excitation Innovation beyond the State-of-the-Art Clearance analysis system will be developed along with new seals, such as retractable, rubbing-tolerant and self-adaptive seals Novel journal bearings with anisotropic design, it will provide sufficient damping / stability while having low mechanical losses TRL

12 WP3 Seals and bearings designs Development and analysis methodology: Results M1 - M14: Conceptual Design of novel bearing and seal arrangement Development of rigs and analysis tools Design and first tests at component level (TRL 4,5) Planned activities for M15 M36: Design and development of rotating rig facilities, testing and evaluation (up to TRL 6) Full engine test verification Full engine analysis for transient operation D 3.1: Adaptive seal concept and rig at KIT WP leader: Alexander Wiedermann D 3.2: Stand body with test bearing 12

13 WP4 Life cycle management Flexibility of the turbine is limited by low cycle (LCF) and thermo-mechanical fatigue (TMF) Limited number of turbine start-ups Limited ramp-up rate Shorter component lifetime, shorter maintenance interval > increased operation and maintenance cost Objectives - to develop and validate fatigue lifetime methods for flexible operational modes with the targeted increase of daily starts and load changes while maintaining life cycle costs at current levels without increasing the risk of costly or even catastrophic engine failures. State-of-the-Art Life predictions are based on simple and therefore conservative methods Lack of detailed knowledge of actual cyclic failure mechanisms in components. Resulting flexibility limitations Innovation beyond the State-of-the-Art Improved fatigue lifetime methods for flexible operational modes Increase of daily starts and load changes while maintaining life cycle costs Longer component lifetime & decrease in operation and maintenance cost More flexible turbo machinery TRL

14 Life cycle management WP4 Life cycle management Results M1 - M14: Fatigue Crack Propagation in Blades and Discs testing (SIEMENS) Accelerated Transient Elastic-Plastic FEA, LCF testing (DSPW) Combined Cycle Fatigue testing (ASEN) Investigation of the effect of high mean stress on fatigue life testing (GE O&G) High Temperature Cyclic Test Rig (HTCTR) detail design started (ASEN Sw.) Planned activities for M15 M36: LCF, TMF and crack propagation testing - continued Thermo Mechanical Fatigue prediction methodology HTCTR implementation and testing (ASEN Sw.) FEA simulation - stresses and strains during transient operation High temperature fatigue testing (LCF, TMF, CCF) Fatigue Crack Initiation and Propagation testing Thermo-mechanical fatigue prediction Verification of lifetime prediction Development and analysis methodology WP leader: Martin Hughes 14

15 CONCLUSION FLEXTURBINE will provide the technology basis for the next generation of flexible turbomachinery essential to enable transition to low carbon-emission power generation TURBO-REFLEX project complementary project (currently being evaluated in H2020-LCE , LCE Competitive Low-Carbon Energy) Optimizing the existing fleet for flexible operation - focus on retrofitting Online plant analytics and monitoring Combining new technology developed in FLEXTURBINE with analytics and field-data based models to enable optimal flexible power plant operation Storage-ready turbine technology Innovation on component and engine level Innovation on plant and system level

16 An OEM Consortium of 22 partners in 7 countries Coordinator: Doosan Škoda Power Contact person: Luboš Prchlík Petr Měšťánek Phone: lubos.prchlik@doosan.com petr.mestanek@doosan.com 16

17 BACKUP TRL 17

18 BACKUP Global Milestones GM1- Initial specifications and generic power plant models for assessment and resulting requirements on component level based on exchange with User Consultation Group (UCG), to be fed into technical WPs (M6) GM2 - Conceptual design review for each component assessed and selected (M12) GM3 - Intermediate assessment as internal technology review involving all technical WPs and UCG (M18) GM4 - Detailed design review for components ready for validation testing (M26) GM5 Validation by test successfully run, and results available for evaluation and assessment (M33) GM6 Final assessment through internal technology review involving all technical WPs and UCG (M35) 18

19 BACKUP Rationale / Objectives Objective 1: Improved flutter-resistant turbine blade design To improve the capability to predict the occurrence of flutter, in particular, at low part load operation, and to contribute to the flutter-free design of the exhaust blades. Thereby, preventing any risk of failure in the machinery and the corresponding outages. Objective 2:Improved seal and bearing designs To optimize the sealing and bearing system of GTs and STs for flexible operation with regard to performance, availability, and increased component lifetime. To enable fast ramp-up while in-creasing the efficiencies by 0.5 %. To reduce both wear in key locations by up to 80 % as well as life cycle cost through increasing service intervals by 30 % to 50 % (maintenance and down-time). Objective 3:Improved live cycle management To develop extended fatigue lifetime of parts for flexible operational modes with the targeted increase of daily starts and load changes while maintaining life cycle costs at current levels. 19

20 BACKUP Key Performance Indicators 20