3rd SEC-Siemens

Technology Forum

Latest Developments of Siemens Heavy Duty Gas Turbines for the

Saudi Arabian Market
Adam Foust, 5000F Package Frame Manager

siemens.com/answers
Restricted © Siemens AG 2014. All rights reserved
Agenda

slide
• 5000F Evolution & Statistics 3

• Design Changes 4

• Package Overview 5

• Gas Turbine Overview 6

• Testing & Verification 7

• 5000F(5ee) Power 9

• 5000F(5) in Saudi Arabia 11

• Fuel Flexibility 12

• Service 14

• Air-cooled Generator 15

• Summary 16
Page 2 Mar-14 3rd SEC-Siemens Technology Forum
 • 80 units in simple cycle
• 30 units in 1x1 cc
SGT6-5000F Evolution • 127 units in 2x1 cc

Successful Heritage of the 5000F Platform • 30 units in 3x1 cc

• 12 units in 4x1 cc

SGT6-5000F Evolution SGT6-5000F Experience

• 279+ units in operation
net power • 9.4+ million operating hours
Turbine
240 Compressor
(minor) • Reliability consistently >99%
(minor) as reported by our customers (230 units)
220 Compressor
F(4) fleet >99.6% reliability
Turbine 501F FC FD FD2 F(3) F(4)
200
Compressor
GTs in
4 36 19 142 49 28
180 Compressor Operation
Hours
158k+ 109k+ 124k+ 96k+ 40k+ 23k+
160 (fleet leader)

SGT6-5000F Introduction year of commercial operation • 34 F(5) units sold (24 units in KSA)
140
• 8 F(5ee) units sold (6 units in KSA)
1993 1997 2001 2005 2009 2013 2015
• 12 F(3i) units sold configured for syngas (10 units in KSA)

Low Risk Evolutionary Design Approach with Proven Reliability

Page 3 Mar-14 3rd SEC-Siemens Technology Forum

SGT6-5000F(4) / F(5) / F(5ee)
Design Features

The F(4), F(5), and F(5ee) Have the Same Firing Temperature

Improved rear stage aerodynamics from F(5) to F(5ee)

• Stage 1 and Stage 2 validated in Service fleet (37K+ hours)
• Similar exhaust on 4000F

Single tie bolt rotor for F(4), F(5), F(5ee)

• 22K+ hours on lead 5000F unit
• Similar single tie bolt rotor on 4000F and 8000H

13-stage compressor for F(4), F(5), F(5ee)

• 22K+ hours on lead 5000F unit

Enlarged compressor inlet from F(4) to F(5)/F(5ee)

• Same compressor in commercial operation on 8000H
• Base load achieved on F(5) in commercial operation

Page 4 Mar-14 3rd SEC-Siemens Technology Forum Restricted © Siemens AG 2014. All rights reserved
SGT6-PAC 5000F
5000F Package Overview

Rotor Air Cooler SGT6-5000F

• Constant cooling air temperature • 232 MW @ +38.8% eff
• Fuel gas heating option • Retrofittable combustion and turbine parts
• Kettle boiler option
Inlet System
• Pulse filter
• Evap cooling

Turning Gear (120 rpm)

• Facilitates a ‘smooth’ start
• Uniform cool down

Air Cooled Generator

• Simplified plant interfaces Starting System
• TEWAC • SFC (air cooled)
• Easy access and maintenance

The SGT6-5000F Package is Well-Suited for the KSA Environment

Page 5 Mar-14 3rd SEC-Siemens Technology Forum

SGT6-5000F
Gas Turbine Design Features

The Most Powerful 60Hz F-Class Gas Turbine in the World

Lowest firing temperature in the market:

• Low NOx emissions
Combustion • Longer part life
• Wide Wobbe operation • Conventionally cast turbine material
• Sub 9ppm emissions (no need for single crystal material)

Compressor High power output on hot days:

• 13 stages • More mass flow via opening IGVs
(no change in firing temperature)

4-stage turbine:
• Reliable part life due to lower
aerodynamic loading when compared to a
Turbine
3-stage turbine at the same power output
• 4-stages
• Conventionally cast parts
Constant rotor cooling air temperature:
• Constant temperature up to 55oC ambient
Rotor • Predictable rotor life regardless of
• Constant rotor cooling air temperature ambient temperature
• Steel discs w/ Hirth serrations

Page 6 Mar-14 3rd SEC-Siemens Technology Forum

SGT6-5000F Development
Testing and Verification Before Implementation

5000F(3) 5000F(4) 5000F(5) 5000F(5ee)

Commercial Commercial Commercial operation Commercial operation

operation in 2005 operation in 2009 in 2014 expected in 2014

Test Date 2003 2005 2006 2013/2014

Off nominal testing…

• Compressor surge limits Turbine Rear Stage Aerodynamics
• Transient operation and Optimized Diffuser Flow Path
• Fuel transfers
• Load rejections

Page 7 Mar-14 3rd SEC-Siemens Technology Forum

SGT6-5000F(5ee) Berlin Testing Update

Mechanical Verification and Performance Testing have been

Successfully Completed in the Berlin Test Facility!

 Performance (base load, part load)

 Operations (start-up, off-speed, trip, restart, etc)

 Combustion stability and emissions

 Turbine row 4 blade flutter

 Rotor dynamics

Page 8 Mar-14 3rd SEC-Siemens Technology Forum

SGT6-5000F(5ee) Power

240 MW The SGT6-5000F(5ee) has High Power Output on Hot Days

Inlet chilling
230 MW
Evap Cooling
(10% rel. humidity)
220 MW

Evap Cooling
210 MW (30% rel. humidity)

200 MW
Evap Cooling
(60% rel. humidity)
190 MW
F(5ee) Power
without TIAC

180 MW
0C 10C 20C 30C 40C 50C
Page 9 Mar-14 3rd SEC-Siemens Technology Forum
First SGT6-5000F(5) Achieves Base Load
And Exceeds Performance Guarantees

240 MW First Fire FSNL runs 232 MW Net Power

220 MW

200 MW Jan 16th, ‘14 Day 2 & 3 Day 4

180 MW

160 MW
5000F(5) gas turbine
140 MW
shipping to the Kingdom

120 MW

100 MW

80 MW
First 5000F(5) gas turbine achieves base load at the
Ras al Khair site in the Kingdom of Saudi Arabia
60 MW

40 MW

20 MW

0 MW

Page 10 Mar-14 3rd SEC-Siemens Technology Forum

Combustion
Fuel Flexible, Reliable, Low Emissions

Siemens is committed to the Energy Demands and Fuel

Flexibility Policies of the Kingdom of Saudi Arabia
Low Btu gas
Syngas ASL Condensate AXL
(~40% inerts)
Testing planned Testing planned Testing tentatively planned
Commercial Operation Tested
(April / May ’14) (April / May ’14) (early 2015)

30 SGT6-5000F units in KSA 10 SGT6-5000F units in KSA

w/ ULN Nozzles w/ DF42 Nozzles
Additional fuel capabilities:
• Bio-diesel
• Natural gas + H2
Page 11 Mar-14 3rd SEC-Siemens Technology Forum
• High Wobbe Index fuels
 Oil Status  Siemens sets a new benchmark for
emissions “25ppm NOx”

“Siemens SGT6-5000F sets a new benchmark in the industry

demonstrating 25ppm NOx emissions on fuel oil.”

45 Competition

40
NOx @ 15% O2 (ppmvd)

35

30

25

20 Siemens ULN

15
0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6
Water to Fuel Ratio

Siemens is the leader in fuel oil technology and has set the benchmark in the industry.

Page 12 Mar-14 3rd SEC-Siemens Technology Forum

 KSA Liquid Fuels

• Viscosity, flashpoint, vapor pressure and Distillation Curves

boiling temperature properties different
than Diesel Oil. Coking Risk
• ASL, AXL, and Condensate evaporate at
lower temperatures compared to standard
Diesel Oil and this creates potential
combustion flashback risk.

Combustion
Flashback Risk
Naphtha

Parameter Distillate#2 ASL Typical

Flashpoint 60oC -25oC
Vapor pressure (40oC) 7.0 kPa 52.7 kPa
Kin. Viscosity (40oC) 3.0 mm2/s 1.25 mm2/s KSA liquid fuels evaporate
Calorific value, lower 43,000 J/g 42,494 J/g faster than diesel oil which
Density (15oC) 840 kg/m3 780.8 kg/m3 causes flashback

Combustion flashback identified as potential risk with light oils (ASL, AXL, Condensate)

Page 13 Mar-14 3rd SEC-Siemens Technology Forum

 Arabian Super Light crude oil
Testing Completed to Guarantee ASL Performance

Rig testing confirmed the 5000F is capable with ASL fuel

1100
Distillation Curves
1000

ASL composition differs from

Boiling Temperature (°F)

900 Diesel Oil

800
Arabian Super Light Crude (ASL) typical diesel oil thus rig testing
700
Khuff Condensate was completed to qualify the fuel
600

500 ASL is 100% vaporized @ ~1,050oF

400 Diesel oil is 100% vaporized @ ~700oF
300

200

100
0 20 40 60 80 100
% Recovered

30o 40o 50o 53o

API Gravity

Diesel Oil AXL ASL Condensate

AmericanPetroleumInstitute Gravity = [141.5 / SpecificGravity ] – 131.5 Full Pressure and Full Firing ASL Rig
Light crude oil has a low specific gravity (high API gravity) Testing Completed in July ’13.
due to the presence of a high proportion of light
hydrocarbon fractions and typically has a low wax content.
Page 14 Mar-14 3rd SEC-Siemens Technology Forum
Arabian Super Light crude oil
Logistics

Testing and Handling of ASL Confirmed that No Pre-treatment

of ASL was Necessary for Pumping or Combustion.

ASL was transported from KSA to Germany in 5

tank-tainers (~755 barrels) and stored at a fuel depot
until the start of testing

Testing facility (tanks and

forwarding system) was modified to
accommodate ASL fuel

Page 15 Mar-14 3rd SEC-Siemens Technology Forum

Arabian Super Light crude oil
Testing Combustion Operability

Testing established that combustion dynamics, flashback, and

emissions on ASL are similar to diesel oil.

No flashback at base load conditions

and 115 bara ASL supply pressure

NOx calibration

W/F ratio NOx emissions

Page 16 Mar-14 3rd SEC-Siemens Technology Forum

Arabian Super Light crude oil
Combustion Operability During Loading

The same ULN combustion system can accommodate diesel

oil and ASL by varying the water / fuel ratio

1.20

1.00
Water / Fuel Ratio

0.80
ASL water / fuel ratio
0.60

0.40
Typical diesel oil water / fuel ratio
0.20

0.00
0% 20% 40% 60% 80% 100%
Normalized Gas Turbine Load

Page 17 Mar-14 3rd SEC-Siemens Technology Forum

 Arabian Super Light crude oil
Auxiliary System

The only modifications in the auxiliary system are the oil pump (suitable
for ASL specific gravity) and the water injection system (higher capacity)
WATER INJECTION PUMP SKID
Hyd 16X

Air • ASL operating temperature should be

filter 16X
the same as diesel oil (5oC to 40oC)
water
Water Injection
• No ASL pretreatment is required (fuel
Pump Gear Box 16X factor accounts for composition
difference to diesel oil)
Hyd
Multi-function
Valve
Water injection pump 16X 16X

ASL Pump

Pilot
filters
16X 16X A
Air B
Drain
System
fuel oil

Hyd
16X 16X

FUEL OIL PUMP SKID

Flow divider

FOWI SKID

Page 18 Mar-14 3rd SEC-Siemens Technology Forum

Liquid Fuel Contaminant Limits

Contaminant limits are valid with project specific configuration,

performance, fuel factors, and service agreements.
Units Suggested Limits1 Rabigh II Diesel oil

Ash ppm 3.0 3.0 0.01% wt

Na + K2 ppm <2.1 2.1 <1.0
Lead ppm <1.0 <1.0 <1.0
Vanadium3 ppm <0.5 0.5 <0.5
Wax4 % 3.0 0.0 N/A
Pour Point oC -30 -35 -23
Cold Filter Plug Point oC -5 -7 -15
Carbon Residue % wt <1.0 <1.0 <0.15
Calcium ppm 10.0 10.0 10.0
Sulfur % wt 0.2 0.1 0.2

1 If
the composition of the actual fuel supplied to the gas turbines exceeds these suggested composition limits, the auxiliary systems and gas
turbine operation may be impacted requiring modification, fuel treatment, or adjustment of the fuel factor.
2 If the suggested Na + K limits exceed 2.1 ppm, an oil washing system can be implemented to reduce levels or the fuel factor applied to
turbine parts can be adjusted based on the validation inspections planned for the lead unit.
3If the suggested Vanadium limits exceed 0.5 ppm, inhibitors can be added to the fuel or the fuel factor applied to turbine parts can be
adjusted based on the validation inspections planned for the lead unit.
4 3.0% wax content is acceptable as long as the Cold Filter Plug Point (CFPP) and Pour Point temperature limits are not exceeded

Page 19 Mar-14 3rd SEC-Siemens Technology Forum Restricted © Siemens AG 2014. All rights reserved
Arabian Super Light crude oil
Test Results Summary

ASL testing has confirmed that reliable base load performance will
be guaranteed with the existing ULN combustion hardware:
• SGT6-5000F(5ee) design is capable with ASL fuel from start-up to base load.
• GT performance and emissions will be guaranteed on ASL fuel.
• The potential risk of combustion flashback was mitigated by varying the water / fuel ratio.
• Service Intervals will be guaranteed with an ASL fuel factor. A fuel factor of 3.0 is applied to
combustor parts only during ASL operation (fuel factor for turbine parts remains at 1.3).

Combustion hardware was instrumented

to measure flashback, dynamics, metal
temperatures, and emissions

Page 20 Mar-14 3rd SEC-Siemens Technology Forum

Gas Turbine Service Intervals
5000F Hot Gas Path Inspection @ 22,000+ Hours

Lower Firing Temperature = Lower Risk in Service Operation

Vane 4

Combustor
Nozzles

Vane 3

Combustor
Basket
Vane 1 Blade 1 Vane 2

F(4) parts shown are

identical to F(5) and
similar to F(5ee)
Page 21 Mar-14 3rd SEC-Siemens Technology Forum
SGen6-1000A
Air Cooled Generator

• Air cooled configurations (OAC and

TEWAC) to meet the environmental
conditions in the region
• 12 OAC in the Kingdom

• Air cooled for simplified plant interfaces

• 30 year design life @ IEEE Class F

temperature rise

Page 22 Mar-14 3rd SEC-Siemens Technology Forum

Thank You from the Orlando, FL, USA Office!

Gas Turbine Manufacturing in the Kingdom of Saudi Arabia

Charlotte, North Carolina, USA Gas Turbines

Dammam, Saudi Arabia

Generators

Steam Turbines
Page 23 Mar-14 3rd SEC-Siemens Technology Forum
Disclaimer

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Page 24 Mar-14 3rd SEC-Siemens Technology Forum Restricted © Siemens AG 2014. All rights reserved