One Year of Commercial Operation in Irsching.pdf

8/16/2019 One Year of Commercial Operation in Irsching.pdf

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Update on Siemens 8000H CCPP Technology and Operational

Experience

Authors:

Dr. Kais Sfar

Siemens Energy, Head of Product Line Marketing Plant Solutions

Armin Staedtler

Siemens Energy, Head of 8000H R&D Program

PowerGen Asia

Bangkok, October 3 – 5, 2012


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Abstract

More than one year ago, the start of commercial operation of “Ulrich Hartmann” power

plant in Irsching (unit #4, Germany) marked the dawn of a new era in combined cyclepower plant construction. For the first time the magic figure of 60% efficiency was

topped. However, not only this world-record efficiency level sparked the interest of the

power generation community, but also the successful optimization of the plant’s

operational flexibility. The high level of plant flexibility is setting benchmarks and

enabling an operating regime, which today already meets the rising demand of the future.

Rapidly increasing share of renewables-based power generation and high fluctuating load

demand – especially in small grids – will require combined cycle power plants able to

provide highest performance at base and part load and at the same capacity for fast

cycling and grid support. Initial tests already demonstrated that the plant exhibits

excellent characteristics in terms of grid stabilization. It was also demonstrated that the

FACY ™ package developed by Siemens enables startup times of less than 30 minutes.

This paper describes Siemens answer to the different regional market requirements and

focus on both the SGT-8000H gas turbine series and the corresponding combined cycle

power plant solutions for the 50Hz and 60Hz regions. The market introduction of the

8000H class technology was based on an extensive validation and test strategy first in

Irsching for the 50Hz frame under real field conditions and later for the 60Hz frame,

which is a direct scale of the SGT5-8000H, in the Berlin test facility. This paper will

further summarize all field validation activities and results, showing how Siemens is

bringing the 8000H to the market based on a comprehensive approach to ensure a risk

minimized market introduction. Finally this paper will describe the current commercial

experience and the first references within the 50Hz and 60Hz markets.


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Table of contents

1. The challenge – Fluctuating power demand at raising

fuel costs 4

2. Siemens 8000H combined cycle power plant solutions 8

2.1. SGT-8000H gas turbine: Proven design with highest efficiency & flexibility 8

2.2. SCC-8000H combined cycle power plant solutions 13

3. Operational experience 19

3.1. Test and validation of the SGT5-8000H and SCC5-8000H 19

3.2. Test and validation of the SGT6-8000H 23

4.

Market launch and first commercial references 27

5. Conclusion 29

6. References 31

7. Copyright 33

8. Disclaimer 33


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1. The challenge – Fluctuating power demand at raising fuel

costs

Considering the worldwide trend of increasing demand for eco-friendly power

generation, a major concern to power producers aiming to build new plants is to

understand the impact of the long-term CO2 reduction targets on the power generation

market of today and the future. Despite all uncertainties related to the potential future

changes in regional environmental policies and CO2 reduction targets, today’s power

plant solutions must be capable of running profitably throughout the whole service life,

which in the case of combined cycle power plants is typically more than 20 years.

Customers expect environmentally-compatible and economical state-of-the-art solutions, which offer a maximum value and long-term investment security, even in a volatile

market environment.

Driven by stringent CO2 reduction targets, the share of renewable energy resources is

rapidly growing. The analysis of the predicted residual load, which is the difference

between incoming renewables-based power supply and power consumption, shows an

extremely fluctuating course over the year. Based on further statistical analysis a clear

shift of the fossil power plants' operating regime from base load towards intermediate

and peak load is predicted. Also, the remaining conventional power plant fleet has to be

able to cope with much higher load ramps and therefore partly serve as backup, e.g. in

case renewables feed-in is interrupted, on short notice.

Considering the ASEAN region, which is characterized by strong economic growth, a

continuous increase of power demand of approx. 6% per annum is anticipated over the

upcoming years. Accordingly, new generating capacities will have to be built to meet thisincrease in the years ahead. Inversely to Europe, renewable energy power generation in

the ASEAN region is still limited and plays a secondarily role within today’s energy mix.

Nevertheless, it is clearly expected that in future the renewable power generation share

will increase. Therefore new future power plant investments have to consider renewable’s

impact at a very early stage of the planning process.

Since natural gas availability in the region is growing, e.g. through the continuous


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extension of the LNG terminals network around the South Pacific Rim, gas fired power

generation plays a key role in securing the energy supply of the region.

Thanks to their outstanding dynamic characteristics, combined cycle power plants are

able to offer highly flexible solutions that can accommodate sharp daily fluctuations in

power consumption. Operational flexibility is based mainly on three major aspects:

– Operational efficiency comprising highest efficiency throughout the whole loadrange and optimized start-up and shut-down operation

– Power on demand comprising rapid availability by fast starts and load ramps

–

Grid support, also comprising load ramps, stable operation in case of gridincidents and backup power

Since gas fired power plants represent a major portion of the energy mix, it is clear that

this type of plant is used to cover a certain portion of the base load needed in the region.

During this load regime highest efficiency is a key requirement to drastically reduce fuel

consumption and, of course, reduce CO2 emissions.


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PowerGen Asia 2012

© Siemens AG 2012

Siemens Energy Sector Bangkok, Oct. 3 – 5

Siemens combined cycle power plants are addressing

the major environmental and economical market drivers

Steep load ramps

and fluctuating

power demand

Gas prices Ecologicalawareness

Lowest investment Highest efficiency Operational flexibility

+ +

Figure 1 Major power plant requirements

The evaluation of the different regional requirements (Figure 1) as discussed earlier leads

to the following key drivers:

– Investment: lower specific investment (EUR/kW) resulting from economies ofscale, while achieving highest reliability and availability.

– Performance: increase combined cycle net efficiency to over 60% with a poweroutput over 550 MW in a 1 on 1, while drastically reducing emissions.

–

Operational flexibility: reduce startup and shutdown times, increase load rampsfor fast load-following ability, improve turn down capability, part-load efficiencyand startup reliability.

These factors have been considered by Siemens Energy in the development of the new

H-Class gas turbine SGT-8000H series and the combined cycle power plant, the SCC-

8000H series, taking both environmental protection as well as economical focus into

consideration. The 8000H program was started in 2000. It was dedicated to consistently

implementing our engineering know-how not only for the gas turbine but also for the


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overall plant solution. Thus, Siemens Energy can provide the right answer to tomorrows’

energy supply needs already today.


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2. Siemens 8000H combined cycle power plant solutions

2.1. SGT-8000H gas turbine: Proven design with highest efficiency &

flexibility

Following the merger of Westinghouse Power Generation with Siemens in 1998, the

decision was made to develop a Next Generation Family of Gas Turbines and therewith

widen the existing product portfolio based on the H class frames for 50Hz and 60Hz

markets (Figure 2). The SGT-8000H series addresses the major market requirements in

terms of efficiency, environmental protection, operational flexibility and economical

value.

PowerGen Asia 2012

© Siemens AG 2012


SGT6-2000E

SGT5-2000E

SGT6-5000F

SGT5-4000F

Output in MW @ ISO conditions

292

200

168

113

375SGT5-8000H

Siemens Large Scale Gas Turbines:

Product Portfolio for 50 Hz and 60 Hz

SGT6-8000H 274

Figure 2 Siemens Energy large scale gas turbine product portfolio

The SGT-8000H gas turbine series combines the best design features and technologies of

the established product lines with some technology innovations and enhancements and is

the result of a continuous optimization and harmonization development activities. The

functional and mechanical design of the engine was built on the extensive experience


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gathered over decades with the predecessor 50Hz and 60Hz engines of both companies

Siemens and former Westinghouse. Proven design features were applied wherever

possible, and “Design for Six Sigma” tools were used throughout the process, to deliver a

robust product which meets all requirements (Figure 3). The results of the 8000H

development, testing and validation activities were also used as an enabler for the

different F class engines upgrades.

PowerGen Asia 2012

© Siemens AG 2012


SGT-8000H engine concept

based on harmonization and new technology

Siemens V Design Siemens W Design

Turbine cylinder

Turbine vane carrier

Exit housing

Front hollow shaft

Bearings

Compressor cylinder

Turbine features

Turbine diffuser

Single tie bolt

Compr. stat. design

Secondary Air

System

ULN can-annular

combustion systemHarmonized

Compressor

The SGT-8000H concept uses proven features from Siemens and (former)

Westinghouse engines and introduces new technology

Figure 3 Concept of the SGT-8000H series

Based on the SGT-8000H frames different packages and plant product configurationsfor both 50Hz and 60Hz markets were developed (Figure 4). A detailed plant solution

view will be discussed in the next chapter.


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PowerGen Asia 2012

© Siemens AG 2012


Configuration and Performance Overview

50 Hz 60 Hz

SGT-PAC 8000H 375 MW 274 MW40 % 40 %

SCC-PAC 8000H 1S 570 MW 410 MW60 % 60 %

SCC-PAC 8000H 2x1 1.145 MW 824 MW60 % 60 %

SCC-PAC 8000H 3x1 - - 1.236 MW- - 60 %

at ISO conditions

SGT5/6-8000H

SCC5/6-8000H 1S

SCC5/6-8000H 2x1

Figure 4 Configuration and performance overview

The basic engine design is summarized in Figure 5 and has the following features, which

account for the high efficiency and the increased operational flexibility: The SGT-8000H

series is an integrated product line with common features and an evolutionary design.

– The engine uses the well known SGT5-4000F disc-type hollow-shaft rotor with a

single tie bolt. The discs are interlocked and centered using Hirth couplings. This

shaft design has smooth and stable running behavior due to the low weight with

high stiffness and uniform thermal expansion under all operating conditions.Siemens has over 16 Million EOHs and more than 750 gas turbines operating

with this type of rotor.

– The 13 stages high efficiency axial compressor is Siemens harmonized design,

which is offered on the SGT6-5000F as well as the SGT-8000H engines. This

design has four variable guide vanes to maintain high part load efficiency and low

emissions. This design continues to offer the ability to replace blades without a


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rotor lift. The 50Hz and 60Hz versions are conceptually identical and are

geometrically scaled.

– The can annular combustion system design is based on the SGT6-5000F and is

purely air-cooled. The existing Siemens fleet with over 400 operating units offers

more than 8,500,000 EOHs of extensive experience with this type of combustion

system. Both 50Hz and 60Hz SGT-8000H engines have a common combustor

assembly.

– The turbine part of the engine consists of four high efficiency stages with air-

cooled turbine blades. Blade R1 uses directionally solidified material and

enhanced TBC system. There is no need for single crystals use and steam cooling. The first stage blade and vane are removable through the combustor without

cover lift. Further measure for improved serviceability and shorter outages is the

use of a single turbine vane carrier. Similar the SGT5-4000F the turbine has a

conical flow path, which allows for hydraulic clearance optimization.

PowerGen Asia 2012

© Siemens AG 2012


> 60% combined

cycle efficiency

Designed for >60% efficiency in combined cycleand best in class operational flexibility

SGT5-8000H

Efficient & Flexible

4 stages of fast acting variable-

pitch guide vanes (VGV) allowing

for improved part load efficiency

and high load transients

Proven rotor design

(Hirth serration,

central tie rod, internal

cooling air passages)

for world class fast

(cold) start and hot

restart capability

High cycling capability due

to fully internally air cooled

turbine section

Evolutionary 3D blading

3D Four stage turbine with

advanced materials and

thermal barrier coating

HCO for reduced

clearance losses

Transient protection of clearances

for reduced degradation with

hydraulic clearance optimization

(HCO) active clearance control

Advanced Can Annular

combustion system

Performance features

Flexibility features

Figure 5 Main design features of the SGT-8000H series


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A key design feature towards operational flexibility and a major concept decision which

had to be made early in the SGT-8000H program, was the selection of the engine cooling

method. Siemens Energy gas turbine portfolio has both types of the major cooling

technologies: The SGT5-4000F and the SGT6-5000F are both based on purely air-cooled

engine concepts, while the SGT6-6000G had a combined air and steam cooled approach.

This experience offered a wide information and experience basis, showing the benefits

and disadvantages of both technologies. Due to the heavy impact of the steam cooling

on the engine operational flexibility and design complexity, the internally fully air-cooled

design was selected for the SGT-8000H. This design feature enables faster starts, since

there is no need to wait for steam from the water/steam cycle. The avoidance of steam

cooling and external coolers enable easier simple cycle and bypass operation, faster load

following and part load operation. Design simplicity especially in terms of sealing designs

provides higher engine robustness. SGT-8000H proven design allows achieving

outstanding performance and operational flexibility without the higher risk associated to

the steam cooling.

A further key aspect which was incorporated in the SGT-8000H was the special focus on

design features to enable easy and quick serviceability:

– Replacement of compressor blades without rotor de-stack or lift

– Roll out/in capability of the turbine vane carrier enables exchange of stationary

turbine hardware without rotor lift

– All turbine blades removable without rotor lift

–

Turbine vane 1 and blade 1 removable without cover lift (access throughcombustion chamber)

– Turbine blade 4 removable without cover lift (towards the exhaust end)


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2.2. SCC-8000H combined cycle power plant solutions

As shown in Figure 4 Siemens Energy offers different combined cycle power plant

configurations based on single- and multi-shaft arrangements. Additionally Siemens is

unique in offering a flexible scope of supply varying between entire power plant (turnkey

scope) over power block / power island and up to an extended power train. This enables

Siemens to add – depending on the project specific setup– the regional partners and local

knowledge (Figure 6). The portfolio flexibility with regards to different arrangements and

scope of supply allows a wide range of technical and commercial (risk and cost)

optimizations, allowing best fit to customer’ requirements.

PowerGen Asia 2012

© Siemens AG 2012


Different scope variations for Siemens combined cycle power plants

Extended

Power TrainPower Island Power Block Entire Power Plant

Figure 6 Siemens offers various scopes to customers adding regional partners & local knowledge

A major solution within the product portfolio is the proven single-shaft design that was

developed in the early 90s. Since then, it has since been successfully implemented in the

F-class (SCC5-4000F 1S) with about 100 units in commercial operation. The power plant

SCC-8000H series was developed based on the SGT-8000H as prime mover, the Irsching

4 test plant and the large F class experience as mentioned above. The design principle

comprising the gas turbine, the generator, the coupling and the steam turbine on a single-

shaft has remained the same, as this continues to offer the customer the greatest

economy and at the same time supreme operational and financial flexibility. The SCC-

8000H series is also characterized by its high degree of harmonization, modularization

and compact design towards footprint and space requirements. Both solutions for 50Hz

and 60Hz markets are based on the same design principles.


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The overall plant design was optimized to provide over 570 MW net power output at

ISO conditions and a net efficiency greater than 60%, while keeping the emissions

extremely low, in this case 25 ppm NOx emissions or less at gas turbine base load (Figure

7). Further performance figures for single and multi-shaft configurations for both 50Hz

and 60Hz are shown in Figure 4.

PowerGen Asia 2012

© Siemens AG 2012


SCC5-8000H 1S designed for η > 60% and highest

operational flexibility

HRSG: BensonTM3Pr/RH 600 °C/170 bar

Steam Turb.:SST5-5000Combined HP/IP

Dual flow LPHP: 170 bar / 600 °CIP: 35 bar / 600 °CLP: 5 bar / 300 °C

Generator: SGen5-3000WWater cooled stator winding

Hydrogen cooled rotor windingMICALASTIC® Stator insulation

World class efficiency

Published DesignTargets:

Performance (net, ISO)Power: >570 MWEfficiency: > 60%

Emissions (Base load)NOx < 25 ppmCO < 10 ppm

Gas Turbine: SGT5-8000H

Figure 7 SCC5-8000H 1S designed for highest efficiency and operational flexibility

Siemens Energy solutions single shaft design is also optimized for CHP applications.Despite the compact design with the floor mounted turbine generator train, it’s possible

to provide up to a three stage steam extraction for heating purposes or process steam.

Figure 8 shows the possible heat extraction of both SCC-8000H product lines. In chapter

4 of this paper a commercial reference of the SCC5-8000H 1S with CHP will be

discussed.


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PowerGen Asia 2012

© Siemens AG 2012


SCC-8000H

Possible heat extraction in large CHP combined cycles

SGT5-8000H

50 100 150 200 250 300 3500 400

SCC6-8000H 1S

SCC5-8000H 1S 570MW

410MW

Possible heat extraction [MWth]

SGT6-8000H

Figure 8 SCC-8000H with combined heat & power (CHP) application

The selected steam turbine type used for SCC-8000H series comprises one combined

HP/IP casing and one double-flow low-pressure casing. The advanced steam turbine

design is optimized for combined cycle applications, providing enhanced transient

thermal behavior for fast loading and fast cycling. For the single shaft configuration the

synchronous self shifting (SSS) clutch allows a self-contained individual turning mode of

the gas turbine and the steam turbine increases the operation flexibility and allows also a

faster start-up of the power plant.

Depending on the frequency and plant configuration different generators within the H2

and H2O cooled product lines are used. Both types are contributing to the overall plant

efficiency increase based on its outstanding performance. Due to the large plant output

the 50Hz single-shaft solution is using – as a unique configuration – a generator with

direct radial hydrogen cooling for the rotor winding and water cooling for the stator

winding. This frame is mainly characterized by its high efficiency and reliability beyond

99%. A start-up frequency converter is used for start-up of the turbine generator unit.


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The generator acts as a motor in the converter mode to start the gas turbine set without

an additional rotating device.

As the SGT5-8000H provides a high exhaust temperature of approximately 625 °C, a

further efficiency increase was achieved based on an advanced three pressure reheat

water steam cycle (up to 600°C inlet temperature and 170 bars inlet pressure) with a

BENSON type heat recovery steam generator (HRSG) and condensate polishing.

Further efficiency improvement measures were based on the use of fuel preheating at

215°C, reduction of pressure losses in the HRSG and piping, feed water pumps with

variable speed drives, etc. The combination of all efficiency improvement measures

enables the major step over 60% efficiency at base load and an efficiency increase of up

to 1,7%-Pt. compared to typical F class over the main operation range.

The Benson-type HRSG for high steam parameters is an essential component in addition

to the "rotating equipment". The HRSG is designed and built by Siemens (Figure 9). As

this component is of major importance for boosting efficiency and flexibility, the

decision was taken to develop and build it in-house on the basis of the available

experience with previous Benson boilers, such as in the projects Karstoe, Simmering and

Timelkam. Due to the increased thermal cycle parameters, advanced high temperature

materials known from the 600 °C steam power plant technology were used for the

HRSG design. For both design standards DIN and ASME Siemens Energy provides

solutions with proven materials for up to 600°C water / steam cycles. Depending on the

plant configuration economics main steam parameters for 50Hz and 60Hz may be

decreased to 150bar and 585°C to enable e.g. the use of a drum type HRSG.


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PowerGen Asia 2012

© Siemens AG 2012


Siemens Benson HRSG

design, 19 units built, e.g.

Malzenice, Gönyü, Severn

Power, Sloe Centrale…

Based on F-class

technology as executed

in e.g. Karstoe,

Simmering, Timelkam

Based on Siemens

BensonTM Technology*

(Elimination of HP drum)

Utilization of high

temperature materials

applied for 600 °C

Steam Power Plants

Proven

Benson

Design

Concept

Benson

Evaporator

Design

HRSG + Plant

Development

in one Hand

=

Innovation based

on proven

technology andmaterials

HRSG with Siemens BensonTM HP section

designed for 600 °C steam temperature

600 °C

Technology

Siemens

Design

Principles

HP pressure/Temp.: 170 bar/600 °C RH pressure/Temp: 35 bar/600 °C

Mass flow: 100 kg/s

Weight: ~ 7000 tons

Heating surface: > 500.000 m²

Irsching 4 BensonTM* HRSG is designed and delivered by Siemens

(*) Siemens is owner of the BensonTM patent

Figure 9 BENSON HRSG designed for 600 °C steam temperature

All flexibility features – well known from our SCC5-4000F series – were implemented in

SCC5-8000H. The FACY (FAst CYcling) concept with its key components is

summarized in Figure 10.


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PowerGen Asia 2012

© Siemens AG 2012


SCC5-8000H 1S – a proven concept optimized for

highest operational flexibility

Proven cycleconcept

Triple pressurereheat cycle

Advanced

steam parameter

Up to 600 °C

Low complexity(No GT external

cooling interface)

FACYFast Cycling

Stack damper

ST stress

controller

HRSG stand-by heating

Condensatepolishing plant

High-capacity

de-superheater

BensonTM

technology

Optimized GT

load ramp

Specific features included in our advanced 8000H plant cycle design for

most flexible and reliable operation

Figure 10 SCC5-8000H 1S optimized design to allow highest operational flexibility

The implementation of the FACY concept in combination with the hot start on-the-fly

allows a hot start-up time reduction down to less than 30 minutes in comparison to

“conventional” hot starts. The concept is based on a procedure for parallel start-up of

gas and steam turbines, while monitoring and controlling the temperature gradients

within limits acceptable for all critical plant components and long term operation

experience with different steam conditions in the Siemens turbine design. A new start-up

sequence, which avoids gas turbine load hold points, was implemented. The main

innovation here is the early steam turbine starting point with earlier acceleration andloading of the turbine. The FACY technology allows for higher number of starts and

faster cycling without compromising plant lifetime consumption.


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3. Operational experience

3.1. Test and validation of the SGT5-8000H and SCC5-8000H

The 8000H program was started in 2000, and after thorough development and

engineering successful component testing paved the way to the first field installation in a

simple cycle configuration built by Siemens for E.ON Kraftwerke in the Irsching site

(Figure 11).

PowerGen Asia 2012© Siemens AG 2012


Irsching Units 1 - 5, as of June 2011Owned by E.ON Kraftwerke

Block #4 – SCC5-8000H 1S

Ulrich Hartmann

Block #5 – SCC5-4000F 2x1

Figure 11 Irsching power plants – Unit 4 built based on SCC5-8000H 1S and the first commercial

SGT5-8000H

First firing took place in December 2007. First synchronization to the grid occurred on

March 7, gas turbine base load was achieved on April 24, 2008, and the field validation

program was successfully completed in August 2009, after over one and a half years in

simple cycle operation. The total 18-month validation program consisted of multiple

measurement campaigns, covering the full operating range starting from hot


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commissioning to a final endurance test in open cycle configuration. This validation

phase confirmed its functionality, operational capability, performance, serviceability,

integrity and stability limits.

Following completion of GT field validation in August 2009, extension and conversion

to a combined cycle power plant started at Irsching and was completed on schedule in

December 2010. The conversion to a complete combined cycle power plant went off

without hitch within a very tight time frame of only 16 months. With the re-ignition of

the gas turbine in its new configuration for the first time in January 2011 and steam

admission just few weeks later, the commissioning phase, including the final test and

validation of the entire combined cycle power plant, was begun. Only few days after this,

in March 2011, it was possible to run the plant at combined cycle base load for the first

time. The further commissioning activities up to June 2011 were marked by tests to

validate the performance of the components and the overall thermal cycle and to

demonstrate the plant's high operational flexibility and capability in meeting the most

stringent grid requirements, to optimize the startup times and load rejections, and to

verify its output and efficiency.

Once all tests were completed, the plant was adjusted to the guarantee conditions, which

were agreed with E.ON in 2005 and increased in 2008 (in terms of output, efficiency,

emissions and startup times). During the customer performance test the plant achieved

for the first time in the history of power plant engineering a net electrical efficiency of

60.4% while producing at the same time a unit net output of 561 MW complying with all

contractually defined emission limits. The achieved efficiency level and the low emissions

(NOx below 25 ppm and CO below 10 ppm) make Irsching 4 – SCC5-8000H 1S a

milestone in environmentally friendly fossil power generation

In terms of operational flexibility following results were achieved under combined cycle

operation conditions:

– Fast hot start-up using FACY TM technology and hot start on the fly: the overall

plant can be very reliably run up to full load in less than 30 minutes, putting over

500 MW in to the grid at combined cycle load ramps up to 50MW/min. It should


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be mentioned that under simple cycle operation conditions, GT full load can be

achieved within 10 minutes at GT load ramps of 35MW/min.

– Plant fast shut down was achieved in less than 30 minutes. During the combined

cycle operation fast plant de-loading was also tested to demonstrate its ability to

run under stable conditions at minimum load (combined cycle load of approx.

100MW or less than 20% of rated output with both GT and steam turbine in

operation).

– Fast cycling dynamic load tests showed excellent capability to effectively

contribute to grid stabilization and to run in a fast load following mode. Load

gradients up to 35 MW/min. were demonstrated and the plant achieved over 200MW load increase and decrease in less than 7 minutes, while all systems were

running under perfectly stable conditions.

– Grid support capability: The UK grid code is the most stringent in the world.

Two major aspects of the UK grid code define the requirements for frequency

response and load stabilization in case of island grid formation. In terms of

primary and secondary frequency response, the Irsching 4 plant surpassed the

UK grid code target as a 12% load increase initiated by a simulated frequency

drop was demonstrated in less than 10 seconds. In order to fulfill the island

formation requirement a load reduction of 45% within 6 seconds as an

instantaneous answer to the detected frequency deviation in the gas turbine

controller was achieved. Such capabilities are indispensable to allow effective grid

stabilization and avoidance of grid blackouts, especially within small grids.

Prior to customer handover world record performance test runs were done. The plant

was operated and tested according to its design conditions. These runs have

demonstrated, also under the supervision and verification of the independent certified

body TÜV, the potential that this plant harbors in this configuration for further planned

commercial projects. The achieved performance at Irsching 4 reference site conditions

were:

– Power output of 578 MW


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– Efficiency of 60.75% (net) with compliance to the emission limits.

Since the customer handover in July 2011, the gas turbine SGT5-8000H has achieved in

the Irsching 4 power plant in sum more than 17,000 equivalent operating hours (whereof

more than 12,5000 EOH in combined cycle operation) and more than 400 starts (Figure

12).

PowerGen Asia 2012

© Siemens AG 2012


Phase I Phase II /

GT Testing (open cycle) Combined cycle plant operation

Starts 85 326

Total EOH 4.365 12.689

Grand Total GT > 17.054 EOH Combined Cycle > 12.689 EOH

Operational Record Ulrich Hartmann CCPP

Irsching unit #4 as of July 30, 2012

Irsching 4 is running with outstanding availability and startup reliability

Figure 12 Operating experience gained in Irsching 4

Since commercial operation two planned short time outages after 6,000 EOHs and 8,000

EOHs were performed and allowed a visual inspection of the hot gas path and

confirmed the anticipated excellent engine conditions. Based on these results the decision

was made to potentially defer the combustor inspection to the 12,000 EOHs outage.

After a further visual inspection at 10,000 EOH finally the combustor inspection took

place during the outage in May 2012. The engine conditions and the hot gas path

components were found to be in excellent conditions. Since then the unit was brought

back in service successfully.


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With start of the commercial operation the combined cycle unit 4 in Irsching

impressively showed its ability as a daily start/stop unit. Figure 13 shows the typical

dispatch situation of Irsching unit 4. Although the plant was designed and sold as a base

load unit, the current dispatch situation can be perfectly matched thanks to the plant’s

capacity in terms of operational flexibility. The plant is typically starting up early in the

morning with the increasing power demand. Over the day the unit is running in a load

following mode with a cycling load profile between full load and 50 – 60% part load at

the time same meeting the emission compliance and expected efficiency. Overnight shut

downs enable our customer to save fuel cost and unnecessary emissions of NOx, CO

and CO2. The intensive monitoring of Irsching 4 shows outstanding plant availability and

starting reliability, which is necessary for a daily cycling operating regime.

PowerGen Asia 2012

© Siemens AG 2012


Operation profile of Irsching 4

Jun. 11 – Jun. 25, 2012

Monday Monday

GT speedPlant output

Figure 13 Typical daily load profiles of Irsching unit #4

3.2. Test and validation of the SGT6-8000H

The SGT6-8000H is a full scaled design (geometry factor 1.2) to the SGT5-8000H. The

major difference is the number of burners (12 instead of 16) and the related design


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adjustments (e.g. casing; transition from burner to turbine vane 1) in order to be able to

use the same combustion system for 50 and 60Hz Version.

Siemens has a vast and long lasting experience in scaling gas turbine design (e.g. SGT5-

2000E/SGT6-2000E or SGT5-4000F/SGT6-4000F). This approach allowed Siemens to

achieve a relative short design phase for the 6-8000H; in fact the design of the SGT6-

8000H was initiated during the validation phase of the SGT5-8000H while the first

commercial contract was signed only 2 years later. Of course the approach to start design

after having already 50Hz validation results available significantly increased the

confidence in achieving the desired design targets. There is still some remaining risk in

scaling, especially for the non-scaled design parts. Examples are turbine inlet temperature

profile; the specific transition-piece from combustor to turbine inlet and even production

processes for the individual parts.

Siemens experience in scaling allows for precise prediction of the items in question.

However, in order to further limit the implementation risk of such a scaled prototype for

both customer and Siemens, it was decided to perform a stringent test- and validation

program also for the SGT6-8000H. Even if the risk for such an event is low, any

unexpected prototype issue will cost both OEM and customer valuable time and money,

if experienced during commissioning in a commercial project. Siemens policy is to avoid

this. Therefore the 60Hz 8000H engine was implemented in the Berlin Test Facility

within the Berlin gas turbine factory. Connected to a water brake instead of a grid

connection via a generator, the engine can be operated at the design frequency of 60Hz

as well as any desired under- and over-frequency despite being located in a 50Hz region.

After a significant rebuilt of the test center in 2010/2011 the first SGT6-8000H was

operated for a ca. 10 months test phase.


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PowerGen Asia 2012

© Siemens AG 2012


Test Bed in Berlin allowing up to 300 MW Testing at various

speed conditions thanks to a water brake concept

Figure 14 Berlin gas turbine test bed facility

Focus of the validation phase was threefold. One target was to confirm the design of the

scaled engine like hardware integrity, thermodynamical behavior, emission profile etc.

Second target was to confirm the validation results of the SGT5-8000H. Third target was

to add some additional test topics that were not conducted in Irsching like oil operation

or sub-25ppm NOx operation. The test program was structured accordingly. The first

test phase consisted of a baseline testing while oil operation or sub-25ppm NOx testing

was conducted after corresponding outages.

The targets of the SGT6-8000H test program were fully achieved. The data retrieved

confirmed both performance prediction of SGT6-8000H and SGT5-8000H; all engine

parameters (temperatures, pressures etc.) were as expected; predicted temperature

profiles were confirmed via thermal paint testing; under- and over-frequency behavior of

the engine was confirmed; operational behavior on both fuel gas and fuel oil did meet the

requirements. Lessons learned from the validation phase are implemented in the

production engines for the commercial projects; as a result any impact on the commercial

projects could be avoided. So it can be concluded that the approach to validate also


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the scaled SGT6-8000H did prove to be beneficial for both Siemens and the Siemens

customers.


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4. Market launch and first commercial references

With the successful conclusion of Irsching 4 and the related validation and testing

phases, Siemens Energy is the first OEM to operate a gas turbine engine and a combinedcycle plant with efficiency far beyond 60%. Siemens impressively demonstrated that

world-record technology is commercially available to the customers and that the 8000H

technology has a clear advance of years on the gas turbine and combined cycle market.

Despite the direct scale approach, the full scale 60Hz engine was tested in the Berlin test

facility, prior to shipment to first customer’s site. Indeed the next commercial success

was achieved in Florida, USA, where 6 units of the SGT6-8000H were placed. Both

Florida Power & Light sites in Riviera Beach and Cape Canaveral are equipped with the

8000H gas turbine in a multi-shaft configuration (3 on 1) and provide approximately

1200 MW electrical energy each. At the same time period the next order from South

Korea for the supply of a complete combined cycle power plant equipped with the

SGT6-8000H in a single shaft configuration was placed by the independent power

producer GS Electric Power & Services, Ltd. As a consortium leader, Siemens is

installing the 400MW class power plant Bugok 3 as a turnkey project. In 2012 further six

units were successfully sold in South Korea, with ANSAN as a multi-shaft configurationand ANDONG, POSCO as a single shaft arrangement. The first 60Hz units will start the

commercial operation already in summer 2013. Following the success in Asia Siemens

Energy has received an order for turnkey erection of the Lausward combined cycle

power plant with district heat extraction in Düsseldorf, Germany. The order was placed

by Stadtwerke Düsseldorf AG (SWD). With an electrical unit output of around 595MW

and a net efficiency of over 61% as a single shaft arrangement, the Lausward CCPP will

set a new world record. In addition, the generated thermal energy will be used for the

district heating system in the city of Düsseldorf. Never before has it been possible to

extract 300 MWth of district heat from a single power plant unit in combined cycle

operation. Thus, the overall efficiency of the natural gas fuel will be around 85 percent.

The Lausward CCPP plant will be one of the most efficient and environmentally

sustainable plants in the world. An overview of the references of the SGT-8000H and

accordingly SCC-8000H is shown in Figure 15 SGT-8000H & SCC-8000H references


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PowerGen Asia 2012

© Siemens AG 2012


SGT-8000H References

Ulrich Hartmann – Irsching 4, Germany 1x SCC5-8000H 1S, >17.000 EOH

Cape Canaveral / Riviera Beach, Florida, USA

2x SCC6-8000H 3x1, COD 05/2013, COD 05/2014

Bugok 3, South Korea

1x SCC6-8000H 1S, COD 08/2013

Status: August 2012

15 SGT-8000H gas turbines sold

Ansan, South Korea

1x SCC6-8000H 2x1, COD 01/2015

Andong, South Korea

1x SCC6-8000H 1S, COD 04/2014

Lausward, Germany

1x SCC5-8000H 1S CHP, COD 02/2016Düsseldorf,´Center

Düsseldorf,´Center

Posco Power 2, South Korea

3x SCC6-8000H 1S, COD 11/2014, 02/2015, 05/2015

Figure 15 SGT-8000H & SCC-8000H references


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5. Conclusion

This paper provides an overview regarding the Siemens SGT-8000H and the related

SCC-8000H series product portfolio. The core engine of Siemens’ H Class is fully air

cooled without having any external interfaces to external coolers. This key design feature

is decisive for shifting the operational flexibility of the overall solution beyond the

existing F Class limits, while providing a net performance far above 60%.

The main elements of the different solutions for 50Hz and 60Hz were presented.

Siemens’ H Class product portfolio is based on single shaft and multi shaft arrangements

with optimized water / steam cycle and live steam parameters up to 600°C and 170 bars.

The product portfolio offers several solutions with a flexible scope of supply, which

drastically reduce life cycle costs and specific investment costs.

The SGT-8000H is fully field tested and validated. An overview about all activities prior

to market introduction was shown and which demonstrates Siemens’ approach in

keeping the overall technology risk and hence customer’s risk at a low level. The Irschingunit #4 has already achieved more than 17,000 EOHs in commercial operation and has

impressively demonstrated the high level of gas turbine and plant availability and starting

reliability. In addition, the full scale 60Hz engine is tested and validated in the Berlin

plant test facility prior to customer’s site shipment in order to limit remaining scaling

risks. The operational records of our field validations and commercial operation have

confirmed our expectations towards engine design reliability.

Siemens 8000H product lines are the result of a long term development program with

significant financial investments, demonstrating Siemens commitment to meet

customer’s expectations and to durably improve customer’s value. Since commercial


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availability 151 units were sold. This great success confirms the achievements in design,

test and validation over more than a decade.

1

Status August 2012


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6. References

[1] F. Eulitz, B. Kuesters, F. Mildner, M. Mittelbach, A. Peters, B. Van den Torn, U.

Walke, P. Rimmington, D. Wasdell, “Design and Validation of a Compressor for aNew generation of Heavy-Duty Gas Turbines”, ASME Power Conference 2007,

POWER2007-22100

[2] P. Ratliff, P. Garbett, W. Fischer, “SGT5-8000H Größerer Kundennutzen durch die

neue Gasturbine von Siemens”, VGB PowerTech, September 2007

[3] U. Gruschka, B. Janus, J. Meisl, M. Huth, S. Wasif, “ULN System for the new SGT5-

8000H gas turbine: Design and High Pressure Rig Test Results”, ASNME Turbo

Expo GT2008-51208

[4] Dr. R. Fischer, P. Ratliff, W. Fischer, “SGT5-8000H – Product Validation at Irsching

Test Center 4” Power-Gen Asia 2008

[5] R. Rudolph, R. Sunshine, M Woodhall, M. Haendler, “INNOVATIVE DESIGN

FEATURES OF THE SGT5-8000H TURBINE AND SECONDARY AIR

SYSTEM” ASME Turbo Expo, June 2009, Orlando, Florida, USA, GT2009-60137

[6] Dr. S. Abens, Dr. F. Eulitz, I. Harzdorf, M. Jeanchen, W. Fischer, R. Rudolph, P.

Garbett, P. Ratliff, “Planning for Extensive Validation of the Siemens H-Class Gas

Turbine SGT5-8000H at the Power Plant Irsching”, ASME Power Conference, July

2009, POWER2009-81082

[7]

W. Fischer, S. Abens, “SGT5-8000H Design and Product Validation at Irsching 4

Test Center”, VGP Power Tec 09/2009

[8] Dr. M. Huth, U. Gruschka, Dr. B. Janus, J. Meisel, “Design of the Combustion

System for the SGT5-8000H and First Experiences in the Irsching Power Plant”,

VGP Power Tech 10/2009

[9] W. Fischer, “SGT5-8000H / IRSCHING 4: On The Way To 60% World Record


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Efficiency And Path To 60 Hz SGT6-8000H”, 18th Conference of the Electric Power

Supply Industry (CEPSI), Taipei, Taiwan, Oct. 2010

[10] Dr. S. Abens, W. Fischer, „SGT5-8000H / IRSCHING 4, On the way to 60 %

World Record Efficiency And Path to 60 Hz SGT6-8000H”, PowerGen Asia,

Singapore, Nov. 2010

[11] L. Balling, Dr. U. Tomschi, A. Pickard, G. Meinecke, “Fast Cycling and Grid Support

Capability of Combined Cycle Power Plants to optimize the Integration of

Renewable Generation into the European Grid: Live examples from projects in NL,

F, UK, D”, PowerGen Europe, Amsterdam, June. 2010

[12] Dr. K. Sfar, T. Hagedorn, “Siemens H Class CCPP Technology: Implementation of

the first 50Hz unit and update on latest 60Hz plant design standard”, PowerGen

Asia, Kuala Lumpur, Sept. 2011

[13] W. Fischer, A. Städtler, “SGT5/6-8000H & SCC5/6-8000H Product Line: Advanced

Generation of High Performance Gas Turbine and Combined Cycle System”, 6th

IDGTE GT Conference, Milton Keynes, November 2011

[14] A. Städtler, “SGT5-8000H/SCC5-8000H 1S First experience of Commercial

Operation at Irsching 4”, Russia Power, Moscow, March 2012

[15] W. Fischer, “SGT-8000H Product Line: Actual Update”, PowerGen Euorpe,

Cologne, Jun. 2012


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7. Copyright

The content of this paper is copyrighted by Siemens AG Energy Sector and is licensed

only to PennWell for publication and distribution. Any inquiries regarding permission touse the content of this paper, in whole or in part, for any purpose must be addressed to

Siemens AG Energy Sector directly.

8. Disclaimer

This document contains forward-looking statements and information – that is,

statements related to future, not past, events. These statements may be identified either

orally or in writing by words as “expects”, “anticipates”, “intends”, “plans”, “believes”,

“seeks”, “estimates”, “will” or words of similar meaning. Such statements are based on

our current expectations and certain assumptions, and are, therefore, subject to certain

risks and uncertainties. A variety of factors, many of which are beyond Siemens’ control,

affect its operations, performance, business strategy and results and could cause the

actual results, performance or achievements of Siemens worldwide to be materially

different from any future results, performance or achievements that may be expressed or

implied by such forward-looking statements. For us, particular uncertainties arise, among

others, from changes in general economic and business conditions, changes in currency

exchange rates and interest rates, introduction of competing products or technologies by

other companies, lack of acceptance of new products or services by customers targeted

by Siemens worldwide, changes in business strategy and various other factors. More

detailed information about certain of these factors is contained in Siemens’ filings with

the SEC, which are available on the Siemens website, www.siemens.com and on the

SEC’s website, www.sec.gov . Should one or more of these risks or uncertaintiesmaterialize, or should underlying assumptions prove incorrect, actual results may vary

materially from those described in the relevant forward-looking statement as anticipated,

believed, estimated, expected, intended, planned or projected. Siemens does not intend

or assume any obligation to update or revise these forward-looking statements in light of

developments which differ from those anticipated. Trademarks mentioned in this

document are the property of Siemens AG, its affiliates or their respective owners.

Documents

One Year of Commercial Operation in Irsching.pdf