MXL for AE94.2 The MXL upgrade allows to obtain the maximum performance improvement (M-mode) and/or to extend the maintenance interval (XL-mode). Thanks to this upgrade, gas turbine owners can maximise performance and reliability, improve operability, flexibility and mainainability of their gas turibne, in order to increase competitiveness in the energy business. The MXL upgrade package can be divided in two different modules: Three Power Ups module CV16 - New stage 16 compressor stator vane Three Power Ups module Radial Displacement System (RDS) Seven Power Ups module New 3D compressor airfoil Seven Power Ups module Advanced coating on turbine vane and blades Seven Power Ups module Inner casing, mixing & combustion chambers up grade Three Power Ups module Inlet Guide Vane (IGV) plus 1 Seven Power Ups module 2 Three Power Ups module Ten Power Ups module 1 Seven Power Ups module 2 Three Power Ups module
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MXL for AE94.2
The MXL upgrade allows to obtain the maximum performance improvement (M-mode) and/or to extend the maintenance interval (XL-mode).Thanks to this upgrade, gas turbine owners can maximise performance and reliability, improve operability, flexibility and mainainability of their gas turibne, in order to increase competitiveness in the energy business.The MXL upgrade package can be divided in two different modules:
Three Power Ups moduleCV16 - New stage 16
compressor stator vane
Three Power Ups moduleRadial Displacement
System (RDS)
Seven Power Ups moduleNew 3D compressor airfoil
Seven Power Ups moduleAdvanced coating on
turbine vane and blades
Seven Power Ups moduleInner casing, mixing & combustion chambers
up gradeThree Power Ups module
Inlet Guide Vane (IGV) plus
1 Seven Power Ups module2 Three Power Ups module
Ten Power Ups module1 Seven Power Ups module
2 Three Power Ups module
Advanced Coatings on Turbine Blade and Vanes• Newbondcoatshavebeendevelopedfor the Thermal Barrier Coating (TBC) of the base material(Ni-basedcasting)inordertoachieve increased protection against high-temperature oxidation and corrosion.
• Prematurewallthinningduetointernal oxidation in the cooling air channels is prevented by aluminizing the cooling air side, using a special internal aluminizing process.
• ThisupgradeisappliedtoTurbineVanesstages 1&2 and Turbine Blades stage 1.
• TurbineVanesstage3areprotectedagainst oxidation by a McrAlY-type coating.
New 3D High Efficiency Compressor Airfoils • ThisupgradeCompressorMassFlowincrease (CMF+)involvesthereplacementofstage0 (IGV),CompressorVanesstage1and2and Compressor Blades stages 1 and 2 with new andadvanced3Dairfoilswhichincreaseboth compressor mass flow and efficiency.
• Thenewprofileallowshigheraxialvelocities combined with a uniform velocity distribution, resulting in a reduced flow separation if compared to the original design.
Inner Casing, Mixing Chamber and Combustion Chamber Upgrade• Innercasing The following complete set of upgrades on the inner casing improves its thermal fatigue response: • Relocationoffixationring • Optimizationofcoolingairpath • IntroductionofThermalBarrierCoating (TBC) on the hub • RadiationLinerwithBellevillespringloaded washers • Introductionofwearresistantcoating
Technical Specifications
How You BenefitThisupgradeisapplicabletoallAE/V94.2/SGT5-2000EGasTurbineModels,withplanningpriortoascheduledMajorOverhaulinspection.
1. Seven Power Ups Module (Upgrade from release 3 to 6)
• Mixingchamberupgrade Additional horizontal guides with hardened shims (yellow rounded) are installed to minimize wear at the mixing chamber/inner casing transition area and thus contribute to extended inspection intervals for the GT. Wear resistant coating has also been introduced to minimize wear on the flame tube interface zones (red rounded).
• CombustionChamberUpgrade To improve thermal fatigue response: • Thermalbarriercoatingappliedonflame tube dome plates and on burner insert ring • Wearresistantcoatingappliedoninterface between burner ring and dome
2. Three Power Ups Module (Upgrade from Release 6 to 6+)
How You BenefitThisupgradeisapplicabletoallAE/V94.2/SGT5-2000EGasTurbineModelswithplanningpriortoascheduledMajorOverhaulinspection.
Inlet Guide Vane (IGV) plusThe Inlet Guide Vane kinematics has beenredesigned in order to allow an increased mass flow to enter the compressor.
Radial Displacement System (RDS)TheRadialDisplacementSystem(RDS)isasystemthat optimizes and controls turbine blade-tip
clearances, increasing power and efficiency of the GT. Clearances are designed for hot restart conditions (worst scenario), but they are not optimized for base load conditions (no transient conditions).Transient regime (see sketch) induces different thermal expansions between stator and rotor components. Clearances need to be large enough to compensate for the non-homogeneous casing deformation which occurs during heating. When the gas turbine is fully and homogeneously
Technical Specifications
Improved mixing chamber
Improved inner casing
Bottom plates
heated, the reduction of the radial clearances in the turbine section causes an efficiency gain in the turbine greater than the loss in the compressor section due to the slightly increased clearances. Lube oil pressure is used to move the rotor into therightposition.Sincetheaxialthrustofthegasturbine is directed towards the turbine, the system is failsafe: in case of oil pressure loss, the axial thrust will move the rotor back into the “safe” position.
New Compressor Stage-16 Stator Vane (CV16)The compressor exhaust diffuser system serves to recover part of the kinetic energy and minimizing the flow inhomogeneity at the combustion chamber inlet. AseriesofCFDcalculationshighlightedsignificanttotal pressure loss and then increased compressor power input. Reducing the compressor’s last vane exit flowangle, it is possible to significantly improve the diffuser behavior. For this purpose AnsaldoEnergia designed a new blade, in order to efficiently deflect the flow by an angle greater than the original one.The new blade was designed starting from the familyofControlledDiffusionAirfoils(CDA).Thebladehasbeen3-Dstackedinordertoimproveits performance, by reducing incidence angle along the full vane span.
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