SIEMENS’ MEDIUM SIZE GAS TURBINES CONTINUED …

Protection notice / Copyright notice© Siemens AG 2009. All rights reserved.

POWER-GEN Europe8-10 June 2010, Amsterdam, The

Netherlands

SIEMENS’ MEDIUM SIZE GAS TURBINES CONTINUED PRODUCT & OPERATION

IMPROVEMENT PROGRAM

Dr. V. Navrotsky, S. Santamaria, O. Andersson

Siemens Industrial Turbomachinery ABFinspong, Sweden

POWER-Gen Europe 2010 Amsterdam Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden

Introduction

Development History & Operating experience

MGT Performance enhancement

Repair solutions

Life extension program

Maintainability Improvement

Summary

Outline


Siemens’ MGT Continued Product and Operation Improvement

Focus on Power plant Profitability and Competitiveness Improvement

Rotating

Equipment

Life Cycle Cost

Reduction

Product

Performance

Enhancement

Maintenance Cost

Reduction

Efficiency Enhancement

Power Output Enhancement

Emissions reduction

Repair & Refurbishment

Maintenance Intervals extension

Maintainability Improvements

Life time extension

Page 4 POWER-Gen Europe 2010 Amsterdam Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden

Home Market

5

7

8

13

17

25

30

47

68

121

157

187

190

253

265

SGT-100

SGT-200

SGT-300

SGT-400

SGT-500

SGT-600

SGT-700

SGT-800

SGT-1000F

SGT-3000E

SGT-2000E

SGT-5000F

SGT-3000F

SGT-6000G

SGT-4000F

Uti

lity

ap

pli

cati

on

Ind

ust

rial ap

plicati

on

SST-9000SST-8000SST-6000SST-5000SST-4000SST-3000SST-1000

1900

1100

1200

700

300

250

200

180+

130+

150

100

85

65

50

10

9

Uti

lity

ap

plica

tio

nIn

du

stri

al ap

pli

cati

on

SST-900SST-800SST-700SST-600SST-500SST-400SST-300SST-200SST-100SST-050

KK&K

SGT5-8000H 340

3

0.45-5

Combined ST Products (MW) Combined GT Products (MW)

Single shaft

STC-SH

STC-SISTC-SOSTC-SP

STC-SR

STC-STOSTC-SVSTC-SX

Integrally geared

STC-GC

STC-GOSTC-GTSTC-GTO

STC-GV

STC-GVT

Compressor for O&G solutions

STC-SPCP

STC-ECO

Siemens turbocompressors

Siemens Product range- Steam Turbines, Gas Turbines & Compressors

Siemens offer a full power range of Steam Turbines,

Gas Turbines & Compressors for Industrial and O&G markets

Siemens’Medium Size Gas Turbines

Industr

ial T

urb

ines

Utilit

y T

urb

ines

31

18,5

25

47

375


SGT- 500- Key Core Engine Features and Experience, Data - January 2010

Mechanical Drive 23,290 bhp

Electrical Output 18.5 MW

Efficiency (PG/MD) 32.2%/ 32.8%

Exhaust Mass flow 92.3 kg/s

Exhaust Temperature 375 0C

2rd generations DLE emission:NOx on gas: < 42 ppmV @15% O2

SGT-500 first introduced (started) 1955.

DLE introduced 1994.

Total of units sold today is 171

- 19 units in Mechanical Drive (MD) application

- 152 units in Power Generation (PG)

Total fleet operating hours > 8 million hours

- > 193 000 of those on DLE

Fleet leaders:

- PG: > 154 000 hours

- MD: > 101 500 hours

15.8 MW, 31%




Efficiency (PG/MD) 34.2%/ 35.1%



2rd generations DLE emission:

NOx on gas: < 25 ppmV @15% O2

NOx on liquid: < 42 ppmV @15% O2


DLE introduced 1991.



- 111 in Power Generation (PG)

Total fleet operating hours > 5.5 million hours

- > 4.1 million of those on DLE

Fleet leaders:

- PG: >145 000 hours

- MD: > 75 000 hours


Availability: 95,5%Reliability: 98,8%




Efficiency (PG/MD) 36.4%/ 37.4 %

Exhaust Mass flow 91 kg/s


3rd generations DLE emission: NOx on gas: <15 ppmV @15% O2NOx on liquid: <42 ppmV @15% O2


DLE standard.



- 19 in Power Generation (PG)

Total fleet operating hours > 200 000 hours

Fleet leaders:

- PG: > 40 000 hours

- MD: > 10 000 hours



New rating 31 MWExisting engines can be upgraded

43 units Sold


Mechanical Drive N/A

Electrical Output (PG) 47 MW

Efficiency (PG) 37.5 %



3rd generations DLE emission:

NOx on gas: < 15 ppmV @15% O2

NOx on liquid: < 42 ppmV @15% O2


DLE standard.


- All in Power Generation (PG)

Total fleet operating hours > 1 000 000 hours

Fleet leaders:

- PG: > 67 000 hours



109 units sold

up to Jan.2010


Introduction



Repair solutions



Summary

Outline


Modified Components:

Compressor blade 1

Turbine blade 1

Turbine vane 1 and 2

Turbine cooling air supply modification:

Swirl generator dimension

Orifice dimension in extraction from

compressor stage #10

SGT-800 Upgrade - 47MW rating

Compressor blade 1

Turbine blade 1 and Turbine vane 1 and 2

Comparison between 47 and 45 MW rating

Ge

ne

rato

r O

utp

ut,

MW

He

at

Ra

te, M

J/k

wh

Compressor Inlet Air Temperature, C

2 MW

Limited modifications enable + 2 MW and + 0.5 % efficiency to support

Customer competitiveness


SGT-700 Upgrade- 31.2 MW rating

The compressor turbine efficiency has been improved by:

Reduced cooling air from areas which has been over cooled

Introduction of TBC - reduced required cooling air

Improved sealing – reduced leakage

Reduction of cooling air and leakages gives

more air to combust and more flow through

vane 1 which results in higher power and

efficiency.

Mature rating test (2008)Stable combustion on all loads and transients

Power, efficiency and emissions confirmed

Function of cooling system confirmed

Component design validated

- 2,2 MW higher power to support higher Power production

- 0,4 % higher efficiency to improve profitability


SGT-500 Upgrade-18.5MW rating

17,2

18,1

18,5

18,8

32,2

32,432,7

33,0

15

16

17

18

19

20

GT23 original 850CGT23 original 865CUprated 865C 865C +1.5% LPT

Po

wer

Ou

tpu

t (M

W)

31

32

33

34

35

36

Ele

ctr

ical

eff

icie

nc

y (

%)

Power OutputElec. Efficiency

Market introductory

Present

data

Increased

TIT

Expected

values

Origina

data

Increased

TIT

Market

Introductory

Max

Potential

Po

wer

Ou

tpu

t [M

W]

Ele

ctr

ical E

ffic

ien

cy [

%]

0,5%~ 2 %

1,3 MW

~ 8 %

Upgrade Approach

The performance of SGT-500 was improved

considerably and with low affords

TIT 865°C. Valid for all old/new SGT-500 fleet:- The HPT stator is replaced with the marine version.- New design of LPT tip clearance.

.

Upgrade objectives

Limited modifications enable + 1.3 MW and + 0.5 % efficiency


MGT Combustor technologies- 2nd and 3rd generation of DLE technology

2nd generation DLE (SGT-600)

3rd generation DLE (MGT)

Combustor Bypass system

MGT DLE technology is effective, simple & reliable

(simple principle with no moving parts or staging )


Introduction



Repair solutions



Summary

Outline


2nd Vane

Burners

1st Blade Combustion Chamber

1st Vane

Abradable rings

Sealing edge repair

Heat shields

Ready

Under development

Sealing edge repair

Current repair status SGT-800- Repairs according to maintenance plan & on condition

SGT-800 repair as a part of Maintenance Program to reduce maintenance cost



Turb blade #1

Honeycomb seals

1st Vane

2nd Vane

Combustion ChamberReady

Under development

Burner

Sealing edge replacement

Comp, recoat abradable rings



Turb blade #1

Honeycomb seals

Sealing edge replacement

1st Vane 2nd Vane

Combustion ChamberComp, recoat abradable rings

Ready

Under development

Comp, blade & vane recoating




Gas collector

Ready

Under development

Fuel injectors

LP & HP comp recoating

Combustor

Flame head


Repair as a part of Maintenance Program to reduce maintenance cost


Introduction



Repair solutions



Summary

Outline


Life Time Assessment

Performed at 80,000 EOH

Level E inspection, with analysis and

evaluation

Status determination of major components:Non-destructive

Destructive tests

Cost optimization of operation

Beyond 120,000 EOH

Life Time Extension120,000 E.O.H. level C inspection with

add-ons:Recommended replacements as agreed with

customer

Upgrade packages as agreed with customer

Life Cycle and Maintenance Improvement - Life Cycle extension – LTA / LTE

Tailored scope of repair & replacement parts for LTE


Level E + LTA

Compressor turbinevanes # 1 & 2

Compressorturbineblades # 1

Combustionchamber

Power turbineblades # 3

Life Cycle and Maintenance Improvement - Life Cycle extension (SGT-600 example)


Introduction



Repair solutions



Summary

Outline


Extended Intervals Maintenance Plan- Extension from 20 000 to 30 000 EOH for all MGT (3 overhauls instead of 5)

OperationMaintenance

10 20 30 40 50 60 70 80 90 100 110 120

Level D

Level C

Level B

Level A

Eqivalent Operating Hrs x 1000

SGT-800 basic Maintenance Plan


10 20 30 40 50 60 70 80 90 100 110 120

Level D

Level C

Level B

Level A




10 20 30 40 50 60 70 80 90 100 110 120

Level D

Level C

Level B

Level A



10 20 30 40 50 60 70 80 90 100 110 120

Level C

Level B

Level A


Equivalent Operating Hours x 1000

SGT-800 Extended Intervals Maintenance Plan

New

2,0%

1,6%

1,4%

Current

3,0%

2,3%

2,0%

POH maintenance/PH*100

1-shift:

2-shift:

2-shift incl. turbine module

The extended intervals MP improve the availability of the MGTs up to 1%

TBO 20 000 EOH TBO 30 000 EOH

+1% AF


Remote Services- Customer support through remote monitoring & diagnostics

Remote Service enabling rotating equipment Life Cycle Cost reduction

Customer Plant

STA-RMS* Platform

Server

Farm

Data

Base

Firewall

Firewall

Countries

Service staff

Firewall

PLC’s

Service staff

New Unit staff

common Remote Service Platform

Data Collector/Win CC

Services that formerly required on-site visits are now

available via data transfer.

The complete spectrum of Siemens IP and O&G

Remote Operational Services is based on the efficient, comprehensive and secure infrastructure of

the SIEMENS common Remote Service Platform.

Today we provide:

Remote Supportconnection is used for checks or to solve problems

Remote Updatestransfer SW to unit to update a component

Remote Monitoringtransfer operation data to central data base and

analyze it, e.g. Vibration, thermodynamics,process data

* STA-RMS =

Siemens Turbo Machinery –Remote Monitoring System

Remote Operational Services at

Siemens Industrial Application


SGT-800 Maintainability improvementDevelopment of Maintenance tools

Compressor dummy:

reduces down-time

improves product safety

Universal lifting tool:reduces down-timesimplifies work

Gear box tools;

reduces down-time

improves safety

Universal table for stator part inspection:reduces down-timesimplifies workimproves safety

MGT Maintainability improvement results in Maintenance cost reduction


Introduction



Repair solutions



Summary

Outline


Summary

Enhancement programs are part of Siemens’ long-term product development

strategy and resulted in:

Sustainable positive operation experience

High reliability & availability

Continued improvements and modifications enable:

extension of engine life-cycle beyond 120,000 EOH (SGT-500 & SGT-600)

extension of maintenance intervals from 20,000 to 30,000 EOH (all MGT).

Extended maintenance intervals from 20,000 to 30,000 EOH enable availability

improvement by 1 %.

The life cycle and maintenance interval extension in combination with the extended scope of

component Reconditioning and Remote Services creates additional opportunity for the

operator to reduce their rotating equipment Life Cycle Cost.


Thank you for your attention!

Documents

SIEMENS’ MEDIUM SIZE GAS TURBINES CONTINUED …