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
Lothar Balling
Gero Meinecke
Andreas Pickard
Dr. Ulrich Tomschi
Siemens AG
PowerGen Europe
June 08-10, 2010

Contents
Summary .................................................................................................................................... 3
Introduction ................................................................................................................................ 4
The power generation market in a period of change.................................................................. 6
Fast Cycling Concept (FACY)................................................................................................... 8
Preserving warm start conditions ................................................................................... 9
Ready-for-operation mode of water/steam cycle ........................................................... 9
Optimized component design and plant operation to reduce material fatigue ............... 9
Automation concept optimization ................................................................................ 10
Second-generation FACY Start on the Fly ............................................................... 10
Recent Operating Results ............................................................................................. 11
Grid Support............................................................................................................................. 12
Load Stabilization at low frequencies .......................................................................... 12
Primary and secondary frequency response ................................................................. 14
Island operation capability ........................................................................................... 15
Customer benefits..................................................................................................................... 17
Conclusion................................................................................................................................ 19

Copyright Siemens AG 2010. All rights reserved.

Summary
Combined-cycle power plants (CCPP) have a large share in todays power generation in
Europe. The increasing contribution of CCPPs to power generation over the past decade can
be explained through their high efficiency, short execution time and relatively low investment
costs.
Meanwhile, regenerative and discontinuous power generation technology like wind power and
solar power is penetrating the market increasingly. Renewable resources certainly lead the
way to reduced CO2 emissions, but on the other hand their limited availability and
predictability pose a considerable challenge to grid stability. Periods of low generation due to
weather conditions (low winds, overcast weather, day and night conditions) have to be
covered by other types, like fossil-fired power plants. As a result, the requirements on
operational flexibility and rapid load response of the existing and new built fossil fleet, as
formulated in grid codes and customer specifications, are constantly increasing. These
developments drive modern power plant design to place a strong focus on operational
flexibility and grid support operation in order to allow a large renewable capacity to be
integrated into the grid systems.
Integration of modern technologies and rigorous optimization of the plant start-up process
have recently enabled Siemens to build most flexible and fastest-starting CCPPs in Europe,
e.g. in France, Netherlands and Germany. This is illustrated by examples presented in this
paper.
In the United Kingdom and similar markets the strict requirements of the grid code on
operational behavior in case of frequency deviations can be met by deploying a range of new
technologies. Island operation and part-load capability are being requested increasingly
throughout developed and emerging markets and these can be provided by introducing
additional and innovative plant control concepts.
Verification and validation of these capabilities was performed not only by theoretical
analysis, but also by live testing during plant operation. This means that the customer benefit
resulting from i.e. reduced fuel consumption and CO2- emissions during the start-up and
ramping process can already be realized in power plants today.
This paper describes the innovations in the area of plant flexibility and the results and
improvements achieved in examplary, recently commissioned combined-cycle power plants
in Europe.

Copyright Siemens AG 2010. All rights reserved.

Introduction
Combined-cycle power plants are one of the more recent developments in the field of fossilfuel power generation. They achieved their current importance in the power generating sector
at the end of the 1980s. This is when power generation started to move away from the closed
monopolistic market structures of the time and towards today's competition-oriented markets.
The relatively low capital cost, high plant efficiency and short construction time are the
main features that make this type of power plant interesting for new investments in a market
characterized by increasingly intense competition.
The first such plants quickly superseded existing older-vintage plants as a result of their
relatively low power generating costs. Initially they were used to meet base-load requirements.
Saturation of the electricity market and an increase in gas prices subsequently resulted in
increased deployment of combined-cycle power plants in the intermediate-load range, i.e.
plants were started up and shut down on a daily basis to cope with daytime peaks.
This new field of application first became apparent at the end of the 1990s in the U.S. and the
United Kingdom. The price of fuel continued to rise due to the large number of plants built
during the boom. Base-load plants which had already been planned were shifted to the load
regime of an intermediate-load plant.
The challenge presented to projects by this changed requirement gave birth to the idea of
trying to improve plant flexibility without compromising plant service life or plant efficiency.
As the market continued to develop, the demand for quicker startups soon followed the
demand for more frequent startups. This market demand finally resulted in the launch of a
development project (FACY FAst CYcling) which combined all the initial engineering
ideas into a single integrated plant concept. The aim of the subsequently inititated R&D
program was to design a plant for an increased number of starts and to reduce startup times. If
possible, no limits were to be placed on the gas turbine by other power plant components,
such as the heat recovery steam generator or steam turbine, during a hot and warm starts.
In the course of the project, potential areas came to light in which further optimization could
be achieved, although these had to wait for a second development generation to be
implemented. The major improvement offered by this second generation involved the startup
procedure. Hold points at which a plant waits until certain steam parameters have been
reached were eliminated as part of the shortened "Start on the Fly" startup procedure. The
steam turbine is now started up parallel to the gas turbine using the first steam which becomes
available after a hot start.
Whereas the first FACY generation reduced startup times for a hot start from 100 to 55
minutes, the second generation succeeded in pushing startup times down below the 40-minute
mark.
The first plants incorporating the advantages of both the first and second generations of the
FACY concept are now being operated commercially. 30-minute startup times were recorded
e.g. at the 2x 430 MW F-class Single Shaft Sloe Centrale plant (NL) during acceptance tests
achieving more than 59% net efficiency. Equally good results have been exhibited by other
reference plants. This means that the expectations placed on the second generation of FACY
have been far surpassed in a number of cases.
Shortening startup times and improving the starting reliability while increasing the number of
starts was only one of many requirements with respect to plant flexibility. The ever increasing
percentage of renewable resources on the grid results in a certain destabilization due to
fluctuations in the availability of these resources. High-availability power plants, such as
combined-cycle plants, are required in order to compensate for these fluctuations. The
requirements with respect to grid support, which are usually defined in a grid code, have

Copyright Siemens AG 2010. All rights reserved.

recently become more rigorous for these reasons. Some of the most stringent requirements are
to be found in the UK grid code. The topics

Load stabilization at low frequencies

Primary and secondary frequency response
Island operation capability

have presented operators with a special challenge for quite some time. Siemens finally
demonstrated with the recently handed over 840 MW Multi-Shaft F-class power plant
Marchwood in UK that the problem could be solved by introducing additional technical
features and optimizing the plant concept without compromising maximum efficiency above
58%.
As with the development of FACY, a decisive success factor was the integrative approach,
which combined the potentials of several systems and components in a single solution. The
challenges were met based on the use of gas turbine compressor and firing reserves and fast
wet compression combined with an optimized I&C/ closed-loop control concept.

Copyright Siemens AG 2010. All rights reserved.

The power generation market in a period of change

Figure 1 shows actual and anticipated development of the electricity production in Europe in
the years 2000 to 2030. The percentage of renewable energy sources (wind and solar) in the
total installed fleet have increased from 2% to 12% over the past ten years.
Electricity Production EU27
Electricity production
[1000 TWh]

Renewables
Hydro

4,5

Fossil
Nuclear

4,0
3,5

7%

3,0

10%

18%
10%

2,5
2,0

54%

48%

29%

24%

1,5
1,0
0,5
0

1995

2000

2005

2010

2015

2020

Figure 1: Europe - expected electricity production

By virtue of their nature, wind and solar energy are not continuously available and difficult to
predict precisely. Reserve power generating capabilities must therefore be provided which can
be activated quickly in the event of failure or limited availability of a renewable energy source
(lack of wind, too much wind or clouds, night etc.).
Fossil-fuel power plants and primarily gas-turbine-driven plants are an obvious choice here as
they can be started up at relatively short notice. The inherent inertia of other types of power
generating facilities is usually much greater, making them largely unsuitable for use as a
rapidly available reserve source of power. There are, of course other fast-responding sources
of power such as pumped-storage power plants. But they do not provide enough capacity to
cover the entire installed generating capability of the renewable power sources in our
european grid system.
If we look into the future, we see the percentage of renewable power generation installed in
Europe increasing to about 30% by 2030. This development is the result of international
commitments (Kyoto protocol) to reduce CO2 emissions. This means that the significance of
the fossil-fuel fleet as a power reserve will continue to grow in the future. Figure 2 illustrates,
how the daily load profile of intermediate load plants (especially gas-turbine driven combined
cycle power plants) is impacted by fluctuating renewable generation on one hand and
changing daily electricity demand on the other hand.

Copyright Siemens AG 2010. All rights reserved.

Daily load profile (schematic)

Peak load:
Pumped Storage,
SCPP/Aero derivative/etc.

Regulation
load

Electricity production

Intermediate load:
Predominantly CCPP

Product Requirements:
Low electricity production
costs
Short startup times
High starting reliability
Good part load behavior

Renewables replace base

load units because of
must feed-in obligations,
but must be backed up
for wind/sun shortfall

Daytime
0

10

12

14

16

18

20

22

24

Base load:
Nuclear, Hydro Running
Water, Coal Steam Plants

Figure 2: Daily load profile (schematic) and impact on CCPP

The new demand for extremely fast power generating availability is also becoming apparent
in our customer assessments. Whereas some customers made absolutely no assessment of
startup times only a few years ago, the assessment figures have increased in recent years in
some projects to over 100,000 /min.

Copyright Siemens AG 2010. All rights reserved.

Fast Cycling Concept (FACY)

As already mentioned, the idea of focusing plant design on an increased number of fast starts
originated from experienced market conditions and executed projects. A multidisciplinary
team of component and plant experts (for the steam turbine, gas turbine, balance of plant and
auxiliary systems, control technology (I&C) and steam generator) was formed around the year
2002 already to identify improvement potential in the existing plant concepts.
The team identified the following potential areas for improvement:
Utilization of different technologies like stack damper, auxiliary steam etc. to maintain
the pressure and temperature in the main components during shutdowns

Ready-for-operation mode of the water/steam cycle by a fully automated start up

concept without manual operation or intervention during hot start

Optimized component design (e.g. high capacity and fast acting de-superheaters) and
plant operation to reduce material fatigue caused by load cycling

Flexible operation concept to allow the operator to predetermine component fatigue

and to choose start up time and ramp rate

Optimization of the automation and control concept

New startup sequence "Start on the Fly" to allow a nearly unrestrained ramp-up

Figure 3 summarizes the main features of the FACY concept.

Figure 3: FACY features

All FACY features mentioned below help to reduce the startup time significantly. They are
modular and will be offered, configured and implemented on a project-specific base.

Copyright Siemens AG 2010. All rights reserved.

Preserving warm start conditions

One of the focus components is the steam generator. Major heat loss occurs through the stack
and therefore a stack damper has been deployed to limit heat loss during shutdown. Cooling
down of the boiler is considerably reduced and delayed.
Furthermore, auxiliary steam can be used to heat the main heat-recovery steam generator
(HRSG). These measures clearly increase the maximum possible shutdown periods during
which criteria for hot and warm starts still apply.
Ready-for-operation mode of water/steam cycle
Auxiliary steam is also used to maintain the water/steam cycle in a ready-for-operation mode.
This means auxiliary steam is fed into the gland steam system of the steam turbine. Keeping
the gland steam system in operation prevents air from being drawn into the steam turbine and
the condenser. Since the steam turbine and the condenser are sealed off from the ambient air,
the condenser vacuum pumps can maintain the vacuum.
To enhance the startup procedure, the condensate polishing plant can be used to bring the
water/steam cycle within specified chemistry limits faster.
Optimized component design and plant operation to reduce material fatigue
The high-pressure drum of the HRSG is one of the most critical components involved in the
startup and ramping procedure. As a thick-walled component it is exposed to large
temperature gradients and high operating pressures. Thermal stress in the high-pressure drum
walls limits the load-, start up- and shut down- gradients of the HRSG.
The main feature of BENSON boiler technology is once-through steam generation, which
means that conventional separation of steam and boiling water inside a boiler drum is not
necessary. Steam is generated directly within the evaporator tubes of the boiler, as shown in
Figure 4. There is no high-pressure drum in a BENSON-type boiler, so these limits do not
apply. A temperature-controlled startup process which uses an optimized high-capacity desuperheater to limit steam temperatures during the startup process has been developed for
warm and cold starts. This reduces thermal stress in critical components of the steam turbine.
The application of BENSON HRSG allows to increase the number of permissable starts and
cycling events over the lifetime by reducing stress induced fatigue in the high pressure section
of the HRSG.

Figure 4: Drum-type HRSG vs. BENSON-type HRSG

Copyright Siemens AG 2010. All rights reserved.

Automation concept optimization

There are two approaches to optimizing the automation concept:

Design limits are enhanced by the use of a closed-loop control instead of earlier
empirical approaches. A turbine stress controller is used to determine thermal stress
based on temperature differences measured within the steam turbine and ensures that
stress limits are not exceeded. The turbine stress controller makes it possible to
shorten the startup time without reducing the lifetime of heat-critical turbine
components.

Two additional startup modes FAST and COST- EFFECTIVE in addition to

the NORMAL- mode were introduced. The operator has the option of choosing the
appropriate startup mode depending on current electricity market prices and operating
and power supply requirements. Maintenance intervals can be extended using
the COST EFFECTIVE setting and the FAST mode permits controlled fast
startup with consequently more frequent service activities.

The startup procedure is automated to a level that enables hot starts with only a few operator
actions, the aim being to minimize inefficient and unproductive periods during startup
preparations. Draining and venting are largely automated.
Second-generation FACY Start on the Fly
In addition to the original FACY concept, a procedure for parallel startup of gas and steam
turbines has been developed. It is based on monitoring and controlling the temperature
gradients within limits acceptable for all critical plant components and the long term operation
experience with different steam conditions in our Siemens turbine design. The new concept
enables plant startups without any gas turbine load hold points. A new startup sequence was
implemented for this reason see Figure 5. The main innovation is the early steam turbine
starting point with earlier acceleration and loading of the turbine.

Figure 5: Improved startup through Start on the Fly

Copyright Siemens AG 2010. All rights reserved.

10

Recent Operating Results

The above desribed features have been implemented across Europe and the second generation
has been showing excellent results in single shaft as well as in multi shaft configurations. As
examples the F-class single shaft plant in Pont sur Sambre (France) and the F-class multi shaft
configuration Irsching 5 (Germany) can be mentioned, as shown in Figures 6 and 7. Both
units have demonstrated their capability to start after a typical over night shut down to full
load in around 30 minutes.
In addition to their excellent dynamic capabilities both units have proven, that fuel efficiency
will not be compromised, since efficiency values above 58% and 59% respectively have been
achieved.
27 min

Figure 6: 430 MW Pont Sur Sambre

(SCC5- 4000F 1S)

It is noteworthy, that the Siemens single shaft operation concept allows a parallel start up of
all plant units individually, resulting in a multiple unit power output (e.g. x times 430 MW)
available in around 30 minutes, as it had been demonstrated in the above mentioned time
frame in the project Sloe Centrale (Netherlands) with 2 units.
Plant Start-up Time ~ 30

Total Plant Load

~ 762 MW

~ 827 MW

GT1/2

ST
ST Load
GT1 Load
GT2 Load

Figure 7: 860 MW Irsching 5 (SCC5- 4000F MS)

Copyright Siemens AG 2010. All rights reserved.

11

Grid Support
In liberalized electricity markets, the minimum requirements with respect to the power
dynamics of power plants are defined in grid codes. Some of the most stringent requirements
imposed on plant dynamics are to be found in the UK grid code due to its island character.
Here we are focusing on three of the most critical dynamic properties:

Load stabilization at low frequencies

Primary and secondary frequency response
Island operation capability

Load Stabilization at low frequencies

Normal fluctuations in the balance between generation and consumption are reflected in
fluctuations in grid frequency which can be compensated by means of regular frequency
control measures. The frequency can, however, also decrease or even increase more
significantly in the event of unusually serious and uncommon disturbances. Unfortunately the
decrease in grid frequency also means a reduction of speed and subsequently a decrease of
power output. This decrease in speed causes the compressor in the gas turbine to transport a
reduced volumetric flow, thus decreasing gas turbine output if appropriate measures are not
implemented to compensate for this behavior which is due to physical reasons. The UK grid
code stipulates that the power output must be maintained for a minimum of 5 minutes down to
49.5 Hz so as to avoid further taxing of the grid due to under-frequency. If a greater decrease
in frequency occurs, the grid code permits a maximum decrease in output of 5 % at 47 Hz, as
illustrated in Figure 8

Figure 8: Load stabilization at low frequency in accordance with UK grid code

To counteract this decrease in power output, Siemens relies on several measures for increased
output which can be implemented at short notice. The decrease in output can be compensated
by rapidly opening the guide vanes on the compressor. The fuel flow is increased at the same
time. This can compensate for a drop in power of around 6 MW. In unfavorable operating
conditions this increase in output will not be sufficient on its own to meet the requirement
described above, however. In this case the Siemens patented fast wet compression concept
can be used to mobilize a further power reserve of around 12 MW. Demineralized water spray
is temporarily injected at the compressor inlet for this purpose. The mass of the injected water
increases the mass flow through the compressor. The evaporating water also cools the air flow
at the compressor inlet. The air density and consequently the mass flow through the
Copyright Siemens AG 2010. All rights reserved.

12

compressor increase due to this cooling process. Rapid activation of the system constitutes a
challenge to control systems, as the increase in power output only takes effect at short notice
if the gas turbine control and the water injection are perfectly coordinated through the
optimized I&C system.
The implementation of these grid support features has been validated and demonstrated in the
F-class multi shaft plant Marchwood (UK) at a power output of about 840 MW and >58%
efficiency (Fig. 9).

Figure 9: 840 MW Marchwood (SCC5-4000F MS)

The measurements from the Marchwood project in UK are illustrated in Figure 10. It can be
seen quite clearly that an 18 MW increase at each GT was achieved by opening the
compressor IGVs and then initiating fast wet compression, thus meeting the requirement of
the UK grid code.

Compressor
Turn Up

Fast Wet
Compression

18 MW with
Fast wet
compression

6 MW by
IGV Control

Simulated Grid
Frequency
Figure 10: Load stabilization at low frequency test per GT (Marchwood)

Copyright Siemens AG 2010. All rights reserved.

13

Primary and secondary frequency response

The purpose of load stabilization at low frequencies was to prevent further destabilization of
the grid when the frequency decreases due to major disturbances. Primary and secondary
frequency response are now required for grid support during normal operation. For this
purpose the UK grid code stipulates that a power plant operating at part load must be capable
of making additional power available on a temporary basis. Figure 11 illustrates the
requirement of the UK grid code. We can see from the diagram that the power plant operating
at under 80 % load must be able to make available at least 10 % of its rated power within 10
seconds in the event of a decrease in frequency. For secondary frequency response 10 % of its
rated power must be made available within 30 seconds. As we can see from Figure 11, the
requirements are reduced in the event of loads over 80 %.
This figure also shows that the load must be reduced by 10 % of its rated power within 10
seconds as a high frequency response in the event of overfrequencies if the grid frequency
rises by 500 MHz. The island operation requirement is, however, even more stringent than
this criterion. For this reason high frequency response will not be discussed any further at this
point.

80% plant load,

primary frequency response,
increase by 10% / 10 s

Figure 11: Frequency response at low and high frequencies in accordance with UK grid code

Unlike load stabilization at low frequency, there is no need to look for a further power reserve
in this case. No new systems are required for this reason. The challenge lies more in the speed
at which the power must be made available.
To meet the requirements of the grid code, Siemens relies on fast repositioning of the
compressor IGVs on the one hand. On the other hand the fuel control has been optimized to
such an extent that load ramps are possible without destabilizing combustion. Figure 12

Copyright Siemens AG 2010. All rights reserved.

14

illustrates the results of the test in Marchwood and clearly shows that the required additional
power is achieved both after 10 seconds and after 30 seconds. In fact, the criterion is
significantly exceeded in both instances.

Primary Secondary
Response Response

53.7 MW in 30 sec
45 MW in 10 sec

Simulated Net
Frequency
Figure 12: Frequency response test at low frequency (Marchwood, July 2009, data for one GT)

Island operation capability

In the preceding sections, the focus has mainly been on increasing power output. With island
operation capability the primary objective is to stabilize the island grid. In this case it may
happen that an excess of power in the island which has formed is suddenly faced with an
abrupt drop in consumption. The grid frequency increases very quickly as a result. The power
plant must react to this frequency increase by throttling power in order to stabilize the
frequency without causing a forced shutdown of the power plant due to over-frequency or any
other uncontrolled process. Uncontrolled shutdown of power plants can result in a grid
collapse.
This is why the UK grid code stipulates that the power plant must be capable of decreasing
from rated power as a worst case scenario to the design minimum operating level (DMOL).
The DMOL must not be smaller than 55 % of rated power in this case. This load reduction
must be effected so quickly that the island frequency remains below 52 Hz. Grid studies based
on the UK National Grid requirements show that the load reduction must take place within
around 8 seconds.
The power plant must detect island formation of this kind automatically and take immediate
action. As soon as island operating mode is activated, permitted load change ramps are set to
the maximum value. The inlet guide vanes in the gas turbine compressor are closed without
delay. At the same time the different closed-loop controls ensure that the power is decreased
at the maximum rate of change for load. The flame stability and potential flash backs in the

Copyright Siemens AG 2010. All rights reserved.

15

combustion system is the main objective of closed-loop control optimization so as to avoid

emergency shutdown of the gas turbine.
As we can see from Figure 13, the gas turbine output was decreased by 52 % within 4 seconds
as the result of a simulated fast frequency increase of 0.9 Hz during the Marchwood test
without initiating a plant trip. A further decrease of 4 % was achieved in the following 4
seconds, thus also more than meeting the second grid code requirement.

Simulated Grid
Frequency
Power Output

Figure 13: Island operating test at Marchwood with one GT

Meanwhile these basic plant features demonstrated in F-class plants are being transferred also to Hclass technology and have already been validated in open cycle operation at Irsching 4 (Germany)
last year (Figure 14), demonstrating that even this latest and highest efficient technology is capable
of supporting the same stringend grid code requirements.

Figure 14: Grid code test at Irsching 4 (SSC5-8000H) in open cycle mode

Copyright Siemens AG 2010. All rights reserved.

16

Customer benefits
The previous sections clearly demonstrate that FACY and Start on the Fly permit a reduction
of startup times as well as operating modes with an increased number of startups. These
features optimize the cycling regime of a plant.
An operating regime which permits a larger number of startups and thus enables nightly
power plant shutdowns offers two additional benefits:

CO2 emissions are minimized by shortening inefficient plant startup times thanks to an
optimized startup procedure. Maximum electrical efficiency is reached faster and total
emissions are reduced.

Since nightly shutdowns and reliable startups become economically feasible, overall
CO2 emissions are further reduced as inefficient overnight parking at part load is
avoided. Other power plants within the grid can then be operated at full load and
maximum efficiency.

Customers benefit from this, primarily through fuel savings and a reduction in CO2 emissions
during the startup phase. Shortening the startup time by using Start on the Fly for a hot start
offers an estimated added value of more than 3 million euros alone, assuming that the savings
described above are realized over the service life of a 430 MW power plant. The option of
disconnecting the plant from the grid overnight offers enormous potential in the form of
savings in operating costs.
Night-time electricity prices are at such a low level in Europe that a combined-cycle power
plant can no longer be operated at a profit during the night due to high gas and CO2 costs (see
Figure 15). In order to minimize these losses, power plants are operated at part load or are
shut down altogether at night.
60

50

40

30

Electricity Price EEX 13.01.2010

20

Gas & CO2 Costs at Full Load

0
0

10

12

14

16

18

20

22

24

Figure 15: Typical electricity price curve (/MWh) compared with gas and CO2 costs (example
from January 13, 2010, European Energy Exchange)

Reducing the load already brings about a significant reduction in losses. However when the
load decreases, so does overall efficiency, meaning that gas and CO2 costs can only be
reduced disproportionately.

Copyright Siemens AG 2010. All rights reserved.

17

In addition to the positive effect of load reduction, shutting a power plant down at night can
achieve other important improvements. Only shutdown and startup costs are incurred by this
method. Restrictions relating to the permitted number of startups for the plant have been
significantly improved with the FACY program. FACY and Start on the Fly have also
significantly reduced startup times. The result is lower gas consumption and lower CO2
emissions, providing the power plant operator with an additional economic benefit for every
start.
Figure 16 shows the CO2 and fuel savings which can be achieved by night-time shutdown
using FACY compared with night-time part-load operation at about 25 %. We can see from
the graphics that the power plant in the example can avoid up to 130 tons of gas consumption
and 362 tons of CO2 emissions per night through night-time shutdown. This increases annual
power plant profit by 4.8 million euros as compared with night-time part-load operation.
Reduction of gas consumption and CO2 emissions [per night]
Gas Consumption [in t]

CO2 Emission [in t]

-130 t
480

43

Part
Load

Shut down &

Start on the Fly

Cost for operation/ shut down

and start up [in million ]

-4,8Mio

-362 t

173

Economic impact [per year]

6,1

118

Part
Load

Shut down &

Start on the
Fly

1,3

Part
Load

Shut down &

Start on the Fly

Based on 200 starts p.a.

Figure 16: Savings of gas and CO2 emissions resulting from night-time shutdown

The calculation example illustrated in Figure 16 is based on a gas price of 20.2 /MWh, CO2
costs of 2.88 /MWh and a night-time electricity price of 29.4 /MWh. The performance data
are based on an SCC5-4000F single-shaft with a cooling tower.
Today grid support features are primarily specified by the grid access requirements of the
individual countries. No monetary valuation of the additional plant flexibility is included in
tender specifications as yet. For this reason today's plants are designed purely based on grid
code specifications. Depending on the level of electricity market liberalization, the different
flexibility features allow to generate additional earnings, first of all by participating in the
frequency reserve market. Furthermore, plants with high reliability and operational flexibility
regarding their behavior under disturbed grid conditions are expected to be prioritized for
dispatch.

Copyright Siemens AG 2010. All rights reserved.

18

Conclusion
Siemens, as an original equipment manufacturer and turnkey power plant provider, has
successfully implemented a new plant feature called FACY to enable highest operational
flexibility with fast startup times and an increased possible number of reliable starts.
FACY is a fully integrated plant concept, which comprises optimizations of turbine design,
heat recovery steam generator, water steam cycle, startup sequence and automation concept.
One of the advanced FACY features is the implementation of a stress controller to enable the
plant operator to choose between fast, normal and cost-effective startup modes, corresponding
service intervalls and life time consumption.
In the light of these preconditions and the high startup reliability of combined-cycle power
plants, daily shutdown and startup with FACY is the most economical solution to reduce the
impact of nightly losses. This maximized operational flexiblity in combination with highest
efficiency over 59% with our SCC5-4000F plant concepts ensures a higher dispatch rate
compared to conventional power plants.
FACY also significantly increases plant startup efficiency and in combination with a nightly
shutdown mode this clearly reduces CO2 emmissions and increases overall power plant
profitability.
In addition to the optimization of startup procedures and an increase in the number of
permitted starts, Siemens offers a plant design which can even meet very stringent grid
requirements, e.g. in the UK. This is only possible if the plant is designed using an integrative
approach. Closed-loop controls allow the plant potentials to be utilized to the full. A fast wet
compression system is activated to maintain power output in the event of low grid frequency.
The Marchwood plant has demonstrated that all the strict UK grid code requirements with
respect to plant flexibility are fulfilled in addition to its top efficiency at more than 58%. The
proven concepts and technologies are now ready for transfer to future F-class and H-class
CCPP projects to support increasing operational flexibility and grid support requirements.
The newly introduced features and concepts help to secure reliable power supply and grid
stability and enable the fast growing market penetration of discontinuous renewable power
generation to further reduce CO2 emissions in Europe.

Copyright Siemens AG 2010. All rights reserved.

19

Permission for use

The content of this paper is copyrighted by Siemens and is licensed to PennWell for
publication and distribution only. Any inquiries regarding permission to use the content of
this paper, in whole or in part, for any purpose must be addressed to Siemens directly.
Disclaimer
These documents contain 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 SECs website, www.sec.gov. Should one or
more of these risks or uncertainties materialize, or should underlying assumptions prove
incorrect, actual results may vary materially from those described in the relevant forwardlooking 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 these documents are the property of Siemens AG, its affiliates or
their respective owners.

Copyright Siemens AG 2010. All rights reserved.

20