Open and

Combined Cycles
Open and Combined Cycles
The new world energy market is leading more and
more toward highly efficient power plants together with
the necessity of fulfill new stringent limits for the envi-
ronmental emissions.
Combined Cycle Power Plants show peculiar advan-
tages in this way allowing fuel economisation throu-
gh the exploitation of the flue gas heat thermal power
produced by the gas turbine upper cycle in a bottom
steam cycle, a larger range of flexibility strategies for
power production, an optimisation of the whole plant
efficiency and a limited environmental impact.
Ansaldo Energia, a distinguished player in the energy
industry, providing reliable and flexible solutions across
a complete and innovative product portfolio in the
power generation field: equipment and plant design,
engineering, manufacturing, contracting, service and
customer assistance.
From design to building - Gebze, 850 MW Open Cycle Power Plant (Turkey)
Ansaldo Energia is the main supplier for power plants
in Italy and deals with international local agencies, In-
dependent Power Producers, industrial customers.
The company is an international turn-key power plant
provider designing and manufacturing several plant
types: thermal, geothermal, combined cycle, cogene-
ration and many activities for nuclear power plants.
According to the market demand, the core business
focuses on combined cycle power plants supplied
in a wide range of generating capacities from 100 to
1,600 MW.
A distinctive feature of Ansaldo Energia is its in-house
manufacturing capability for all major plant compo-
nents, such as gas and steam turbines and generators,
while the other plant components, such as HRSGs,
condensers and plant auxiliaries are purchased from
selected suppliers.
Sousse C, 400MW Combined Cycle Power Plant (Tunisia)

Scope of Supply
BOP
Ansaldo Energia offers multiple choices depending on TURNKEY PLANT
client exigencies and requirements.
In particular:
• the turboset package can be supplied as a standalone THERMAL CYCLE EQUIPMENT
system together with the electrical generator, POWER ISLAND
the turboset auxiliaries and the control system;
• it can be integrated with thermal cycle equipments to
TURBOSET AUXILIARIES
provide a complete power island. The power island
TURBOSET PACKAGE
supply includes design, erection and commissioning
of gas and steam turbine set, HRSG and all the other
components and systems involved in the plant TURBINE GENERATOR
performances and availability;
• it can be extended including all the components The above statements are represented in the following
and systems in a complete turnkey power plant figure.
both in combined cycle or open cycle configuration Ansaldo Energia modular approach combines the be-
providing personalized and optimised layout nefits of a pre-engineered combined cycle design with
solution using a flexible approach to cope standard the flexibility needed for customisation according to
solutions, specifically applicable to power block, with specific site or Client requirements, as well as allowing
customer and site requirements following safety, to adapt the solutions on the offer to maximise custo-
operability and maintainability criteria. mer satisfaction.
Combined Cycle

Plant configurations Combined cycle for electrical

and Solutions energy production only
Ansaldo Energia supplies combined cycles in different Combined cycle for both electrical and heat po-
configurations: wer production for cogeneration for industrial purpo-
ses or district heating applications using controlled or
1+1 both in multi shaft and single shaft arrange- uncontrolled steam extractions from steam turbine or
ment. In multi shaft arrangement both the gas turbine from HRSG;
and the steam turbine are each connected to a dedica-
ted generator. In single shaft arrangement the gas turbi- Combined cycle solutions can be also adopted
ne and the steam turbine drive the same generator, with when low LHV gas are available from an industrial
the advantage of many common auxiliary systems. park, as blast furnace gas (BFG), refinery off-gas, syn-
thesis gas (syngas), in order to employ the gas high tem-
peratures and mass flows to produce process steam.

Combined cycle with HRSG supplementary firing

or fresh air: supplementary firing is provided in case
of additional thermal or electrical power requests for
peak load operation while, during GT stand-by pe-
riod, fresh air systems can provide electrical or thermal
energy from the steam cycle; this last solution is most
commonly adopted in application with low LHV gases.

2+1 multi shaft arrangement Repowering of existing conventional units

This configuration is composed by two gas turbines, each
with its own HRSG, a single steam turbine with its steam
condenser. This solution allows more flexibility during the
operation, because in case of low power demand, a gas
turbine and its associated HRSG can be excluded, while
the other group operates at full power keeping high flue
gas temperature, resulting in high steam temperature.
These configurations can be combined together to reach
different aims following client requirements:
Ansaldo Energia has acquired many skills in repo-
wering from ageing conventional coal/oil fired power
plants to modern and efficient combined cycles.
In the new electricity market it has become mandatory
to have in operation very competitive power stations
with high efficiency, high flexibility and low investment
cost: the emissions reduction deriving from the use of
natural gas in latest generation technology gas turbi-
nes together with the higher efficiency and the expan-
ding capacity of combined cycles are key factors for
this choice, togheter with the economical advantages
in recovering the existing steam cycle main compo-
nents, such as the steam turbine, the heat condenser
and also the auxiliaries and piping still standing.
Flexibility
Flexiblity to meet the requirements of the new free elec-
tric market. New power plants should have long lifeti-
me and high flexibility to hold heavy and continuous
load cycles with frequent daily start-up and shut-down.
Ansaldo Energia designs power plants from base load
to reliable daily start-up and shut down with its proper
features.
Flexibility packages to be retrofitted on existing combi-
ned cycles have been studied to obtain flexible power
plants reaching the following aims: plant grid support
improvement; minimum environmental load reduction;
start-up time reduction and start up-time procedure
optimisation. The above packages can be provided alone
or together depending on client requirements.

Exhaust Gases
Triple Pressure
Heat Recovery
Steam Generator
Air

Generator

Air Compressor Gas Turbine

Natural Gas

Generator

Condenser
Steam Turbine

Turano Lodigiano, 800 MW Combined Cycle Power Plant (Italy)

Combined Cycle Performance

Combined Plant No. & Type Net Plant Net Plant Net Plant GT Power ST Power Grid Notes
Cycle Model Config. of GTS Power Output Efficiency Heat Rate Output Output Freq.
[MW] [%] [kJ/kWh] [MW] [MW] [Hz]

1AE643-CC1M 1+1 1 x AE64.3A 111.7 53.75 6698 73.6 40.2 50/60

2AE643-CC1M 2+1 2 x AE64.3A 223.7 53.82 6689 147.1 80.6 50/60 ISO
conditions
1AE942-CC1M 1+1 1 x AE94.2 277.4 54.57 6597 180.9 101.6 50
with sea
2AE942-CC1M 2+1 2 x AE94.2 557.8 54.87 6561 361.7 206.1 50 water
1AE943-CC1M 1+1 1 x AE94.3A 456.4 58.86 6116 306.0 157.9 50 condenser
2AE943-CC1M 2+1 2 x AE94.3A 913.2 58.88 6114 610.4 317.8 50
Open Cycle

Ansaldo Energia is also skilled in supplying complete Exhaust Gases

open cycles on tunkey basis. The open cycle differs

from a combined cycle since no provision for waste
heat recovery is foreseen, therefore it is based only on
the gas turbine package, with proper accessories for Air
fuel treatment, where the exhaust flow is directly con-
veyed to a stack. For this reason the open cycle plant Generator
has a cheaper cost since it requires smaller power capi-
tal investment and it can be scaled, using one or more
modules of gas turbine packages, to generate small or
Air Gas Turbine
large amounts of power. The open cycle allows a quick Compressor

installation, few months compared to years normally Natural Gas

required for a combined cycle power plant.
Another feature of the open cycle is the ability to be
turned on and off within minutes, supplying power only
when required with no need to keep the gas turbine
operating when the energy is not so remunerative.
Combining the above features with the high reliability
levels, the open cycle is particularly suited for peaking
power plant or reserve plants with an excellent capabi-
lity in grid support and stabilisation.

Simple Cycle Performances

With GT Model Plant Config. Net Plant Net Plant Net Plant Heat Grid Freq.
Power Output Efficiency Rate [Hz]
[MW] [%] [kJ/kWh]
AE64.3A 1 GT 72.6 35.09 10261 50/60
AE94.2 1 GT 181 35.60 10114 50
AE94.3A 1 GT 304 39.35 9148 50

@ ISO conditions, natural gas operation

6th October, 600 MW Open Cycle Power Plant (Egypt)

Environmental Impact
More and more stringent environmental constraints set
by international and local regulators have induced com-
bined cycle manufacturers to develop innovative solu-
tions to reduce plant environmental impact:
Lower flue gas emissions
Ansaldo Energia gas turbine models, fuelled by fuel gas
and equipped with Hybryd Burner combustion system,
achieve less than 50 mg/Nm3 NOx emissions and less
than 30 mg/Nm3 CO emissions. Ansaldo Energia has
successfully designed upgraded burners that reduce
emissions significantly and guarantee the same reliabili-
ty and availability, achieving guaranteed NOx emissions
lower than 30 mg/Nm3. Thanks to its Research and De-
velopment division dedicated to combustion technolo-
gies, Ansaldo Energia has developed VeLoNOxTM (Very
Low NOxTM), the new combustion system.
Noise
An evolving issue in power plant design and siting is
the noise control. Ansaldo Energia takes care of plant
acoustic design, providing innovative engineered solu-
tions to noise problems at the lowest disposable costs.
Plant acoustic balance is constantly checked during the
whole design process, in order to satisfy law require-
ments and clients’ needs.
Zero liquid discharge
Ansaldo Energia, respecting the most stringent envi-
ronmental normative and active in the research against
In few words
Ansaldo Energia combined cycle design approach sa-
tisfies the new market requirements deriving from the
privatisation of the energy market with the key design
factors in achieving a swift return on invested capital,
included capital cost, fuel consumption, operation and
maintenance criteria, as well as the consumer demand
profile or grid regulations. Other Ansaldo Energia ca-
pabilities, including specific engineering tools like RAM
(Reliability, Availability, Maintainability) analysis, plant
dynamic analysis and remote control, flexibilization, are
also used during configuration design to define plant
water resources pollution, has conceived CRIOSR, the
proprietary ZLD system to reduce the needs for fresh
water consumption and to comply with the local regula-
tion that prohibits any liquid effluents emission from the
industrial sites. The system allows a total recovery of
the industrial discharge water except the physiological
losses of the plant with a R.O. (Reverse Osmosis) sec-
tion efficiency of about 98%. The system is composed
by the following sections: biological treatment, oily wa-
ter treatment, neutralisation treatment, demineralisation
system and brine treatment.
Architectural solutions
Ansaldo Energia in the last years has gained many skills
in implementing architectural solutions using a suitable
and flexible approach to meet client’s distinctive cha-
racter and expectations. Ansaldo Energia takes care of
the land’s social-cultural framework in order to promote
plant acceptance and territorial integration.
Architectural details of Napoli Levante 400 MW
Combined Cycle Power Plant (Italy)
behaviour in transient conditions, optimise the mainte-
nance program, increase availability and improve net
dependable capacity.
Additionally, Ansaldo Energia is improving, with a gre-
at effort in research and development, combined cycle
main components design such as gas turbine upgra-
ding, new materials/coatings, new low emissions bur-
ners, steam turbine new last stage blades, new air co-
oled generators up to 400 MVA and hydrogen cooled
generators up to 550 MVA to better satisfy its clients’
requirements.
Ansaldo Energia Reference
Open and in the World
Combined Cycles

Petergraf
UNITED KINGDOM
2 EPC
600 MW C.C.

TURKEY

02/2014
FRANCE
1 EPC 1 EPC
400 MW C.C. 850 MW C.C.

Stampa: Microart Recco - Genova

SPAIN
1 Power Block
800 MW C.C.

Egypt
2 EPC
1200 MW O.C.

TUNISIA
ITALY ALGERIA 2 EPC
15 EPC 16 EPC 800 MW C.C.
6800 MW C.C. 2800 MW O.C.

13 Power Blocks
4850 MW C.C.

CHILE
1 EPC
250 MW C.C.
South Africa
2 EPC
900 MW O.C.

EPC & Power Block Power Plant Supply with Ansaldo Energia Gas Turbines (last 15 years)
>50
2014 1Q Summary

16152 Genova - Via N. Lorenzi, 8 - Italy

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