Innovacin en Servicios en Generacin de Energa Modernizacin - Oliver Neukrantz

Energy - Día de la Innovación
Oliver Neukrantz
© Siemens AG 2010. All rights reserved.

Agenda
1. Frame Portfolio
2. Maintenance Concepts - Update
3. Engineering, R&D and Modernization
4. Life Time Extension

Gas Turbine Development Path
 V-Frames 50/60Hz and Future Frames 50Hz
More than 700 units in commercial operation worldwide! *
SGT5-3000E (V94.2A)
2000
SGTx-4000F (Vx4.3A) SGT5-8000H

Technology
1996 2007
V84.3
1994
V64.3
1990 V94.3
1995
SGT6-2000E (V84.2) SGT-1000F (V64.3A)
V94.1 1989 1997
1980
V82.0
SGT5-2000E (V94.2)
V94.0 1981
1974
V43
VM5 V93.0
1972
VM1 1960
1956
VM80
1961
1960 1965 1970 1975 1980 1985 1990 1995 2000 2005 2010
Years
* V-Technology, large Scale, As of May 2010
Page 3 July 2010 Energy - Día de la Innovación Neukrantz AL =N ECCN =N
Siemens Gas Turbines –
Complete Product Portfolio for 50 Hz and 60 Hz
SGT5-8000H 375
SGT5-4000F 292
SGT6-8000H 274
SGT6-5000F 208
SGT5-2000E 168
SGT6-2000E 113
SGT-800 47
SGT-700 31
SGT-600 25
SGT-500 17
SGT-400 13
SGT-300 Output in MW @ ISO conditions
8
SGT-200 Large-scale gas turbines
7
SGT-100 Industrial gas turbines
5
Extension of our product portfolio to satisfy customer demands

SGT5-4000F / V94.3A Gas Turbine
Customer Driven Product Development
• Firing Temperature Increase

• Improved Hot Gas Parts 2008
[292 MW; 39,8 % 4) ]
• Burner Upgrade (Low-NOx  Premix-Pilot)
• Cooling Air Reduced Combustion Chamber
• Burner Upgrade (Reduced Swirl)
• Fuel Gas Preheating
Efficiency
2005
• Compressor Mass Flow Increase
2004
• Turndown 2003
• Hydraulic Clearance Optimization
• HR3 Burner 1997 3)
170 Units in Commercial Operation 1)

Total EOH > 5.636.000
Lead Unit EOH > 104.000 Ongoing Development
1996 2)
[240 MW; 37,0 %]
• Further Firing Temperature Increase
Power Output
Additional Modernization & Upgrades
• Advanced Compressor Coating • Advanced Compressor Cleaning System • Wet Compression
• EVAP Cooler • Foreign Object Detection System • Fuel Conversion
1) Source: Framebook as of June 2010 2) 17-stage compressor
3) Since 1998: 15-stage compressor 4) Expected values only, site specific values may vary

SGT5-2000E / V94.2 Gas Turbine
Customer Driven Product Development
• Siemens innovative 3D
Blades and Vanes 1+2 2008
[173 MW; 35,8 %**]
• Compressor Mass Flow Increase
• 41MAC 2001
2006
• Turbine Section Upgrade
Efficiency
• HR3 Burner 2003

• 33MAC 1998
1996 • Wet Compression
198 Units in Commercial Operation*
Total EOH > 13.212.000 • Siemens innovative 3D
Lead Unit EOH > 260.000 Blades and Vanes 3+4
Ongoing Development
1981
[118 MW; 32,4 %]
• Hydraulic Clearance Optimization
Power Output
Additional Modernization & Upgrades
• Advanced Compressor Coating • Fuel Gas Preheating • Fuel Conversion
• EVAP Cooler
* Source: Framebook as of June 2010

** Expected values only, site specific values may vary

Agenda
1. Frame Portfolio

Development of Outage Durations
(standard work scope, without findings)
100
90
Introduction of
IndexOutageDuration(2001=100)
Major
80
HGPI* concept eHGPI
HGPI
70
60
50
40
30
2001 2002 2003 2004 2005 2006 2007 2008 2009 Ye ar
*HGPI = Hot Gas Path Inspection,

eHGPI = extended Hot Gas Path Inspection
Development of Maintenance Schedule
Example SGT5-2000E
25 50 75 100 k EOH
25 M AC Concept, 4 kEOH Minor Inspection Interval
based on
GT-Availability: 94,7% * EOH
Major Major Major LTE

SGT5-2000E
Advanced mixing chamber New coatings
GT-Availability:design
96,8% *, optimized power output
on turbine based on EOH
blades and
HGPI (or Major) eHGPI (or Major) LTE
vanes stage 1
HR3 burner & turbine
and flame tube
Recoating of compressor vanes stage 2,
modification
bladesAdvanced
stages 1 inner casing
– 6 and new blades
compressor design
vanes stages
GT-Availability: 97,3% *, optimized availability based on EOH
0 – 3 every 41,000 EOH Caulking of compressor
Major Major new vanes, new blades
* based on planned outage days only, for 100 kEOH operation period © Siemens AG 2010. All rights reserved.
Development of availability, example SGT5-2000E
Development of availability
3 %
Combined >
effect on GT Δ
availability:*
41MAC
%
33MAC
pastpast
(2001) today, 33MAC today, 41MAC
Availability* increase of
* based on planned outage days and standard more than 3 percentage points
workscope only
Serviceability of Power Plants –
Example of Multi-Outage on Single Shaft Configuration
ZGK 039
Storage area
Storage area outside UMC outside UMC
Container Container Container Container Container Container Container Container
Rolling Rolling
Shutter „A“ clearance Wende- +/- 0,00m Shutter „B“
Trailer wvor-
mw
v14
v13
v12
v11
v3
v2
t2
v15
v10
v9
v8
v7
v6
v5
v4
v1
t4
t3
t1
&n Trailer
3000 x 4500 7500 7500 x 7600
richtung
W xH W xH
Con Container Container

Con tai n +4,50m
tai n er
er
Storage area
outside UMC
Outage duration dependant on plant layout – longer than longest single event.
Total area need for infrastructure, workspace and storage: 5.500 m²
Agenda
1. Frame Portfolio

Customer’s Needs are our Market Drivers!
Efficiency Increase
Emission
Reduction
Operational Efficiency
Flexibility Increase
Customer
Customer
Needs
Needs
Availability Increase Power Increase
25
Reliability & 50 75 1 00 k EOH
Power Recovery by upg rade
Power Increase
2 5 MAC Conc ept , 4 kEOH Minor Ins pec tion Int erva l
Availability
G T-Availab ility: 94,7% *
based on
EOH
100%Increase
Ma jor Major Major LTE
SG T5-2000E
3 3 MAC Conc ept, 8 kEOH MinorI ns pe cti on Interva l
ba se d on E OH
Degrading by aging
GT -A va ilability : 96,8 % *, optimize d power out put
Power output
HGPI (or Ma jor) eHGPI ( orMajor) LTE
Reco very b y overh aul
4 1 MAC Conc ept, 8 kEOH MinorI ns pe cti on Interva l
Degra ding b y fouling
GT -Availability : 97,3 % *, opt imize dav aila bility
Maintenance
based o n EOH
Ma jor Major
Operatio n hours
Cost Reduction
Comprehensive OEM Engineering Support
main locations Engineering Support
Analysis Evaluation
Product
Fleet
Change
Data
Base Manage
Analysis -ment
Checklists
The Product Development Process (PDP) @ Siemens
Customer Feedback Gate 1 Gate 2 Gate 3 Gate 4 Gate 5
Design Validation
Market Demand Product Planning
Planning
P roduct P rod.&Dev elop.
Design
Prep. Implementation
Conceptual Basic
Preparation
Commerciali-
Desi gn Implementation
Final Design, Manufacturing Installation, Product
Validation
Perfor mance
Str ategy P lanning Design Design zation P lanning P rocurem ent & As sembly Trial Operation Monitoring Validation
M00 M10 M20 M30 M40 M50 M60 M70 M80 M90 M100
time
Fleet Experience
R0 R1 R2 R3 R4 R5 R6 R7 R8 R9 R10
Single Events Minimizing risks by conducting mandatory reviews in interdisciplinary teams (e.g.
marketing, engineering, manufacturing, service …)
Reported From Sites
Engineered Solution:
Specific Solution, Fleet Solution, M&U-Product
© Siemens AG 2010. All rights re served.

Customer Survey - Customer Feedback
Asses Voice User Group

Analysis Improvement
of Customers Meeting
Customer Feedback
• Anonym ous • Descriptive and • Internal feedback to respons ible process owners • Presentation
web survey explorative • Initiation of improvement processes of results and
• Conducted statistics • Information of sales and feedback to customers improvem ent
by third party • Content analysis to support interaction activities
1 Month
Invitation
email 2 Month
Survey
completion 2 Month
Results User Group
Meeting
4 Month
Customer 1 Month
Feedback
UGM Documentation
(Mailing & CEP)
10 Month
SGT5-4000F / V94.3A
Example: Starting Reliability Package
Customer Feedback
Drivers for Development
SGT5-4000F
1 2 3
1 2 3
1 Analysis of over 93 units

2 Improve most frequently sources of error
3 Started implementation
SGT5-4000F / V94.3A
Starting Reliability Package
Customer Feedback
Generic Hardware Scope
 New igniter design

 Exchange of ignition cable holder
 New ignition logic with constant ignition
speed
 Online ignition monitoring
 Drying procedure after compressor
offline washing
 Automatic drainage system
 Blow-off valves with larger actuator
 Modified flame monitoring system
 Installation during major outage

recommended

SGT5-4000F: Improvement in Starting Reliability
Starting Reliability Package
Customer Feedback
Change of starting reliability after implementation of measures
Site A Outage in September 2008

Starting reliability before outage => 44%
Starting reliability after outage => 100%
(1 Start abbort due to tuning activities excluded)
Site B Outage in January 2009

Starting- reliability before outage => 33%
Starting reliability after outage => 100%
 Effectiveness of Starting Reliability Package validated.
Ready for Fleet Wide Implementation


Design
Conceptual Basic
Preparation
Commerciali-
Validation
Perfor mance
M00 M10 M20 M30 M40 M50 M60 M70 M80 M90 M100
Fleet Experience
R0 R1 R2 R3 R4 R5 R6 R7 R8 R9 R10
Reported From Sites

Compressor
Compressor Types
SGT5-4000F 15 stage
• 15-stage compressor with

transonic front stages
• Pressure Ratio: ~17-18
Fleet Experience
• 17-stage compressor with

supercritical blades in stages
1 and 2
• Pressure Ratio: ~16
V94.3A 17 stage
Compressor Stator Rings
Design Concept Fleet Experience
Outer
Ring
Compressor
Ring Segment Vane
Compressor
vanes
• 1 Outer Ring
• Vanes Inner
Ring II
• 2 Inner Rings
Inner Ring
I
Inner Ring
II weld
Inner
Ring I

Vane Hook Crack Findings Fleet Experience
Possible Issue:
 Single vane hook cracking at some front stages.
 In very rare cases airfoil breakouts with downstream
compressor findings.
(Repair measures performed during regular outages
using boroscopic compressor inspection as mitigation
measures.)
Root Cause:
 Increased local surface stresses in the
hook due to constrained deflection with
contributing factors as surface finish /
undefined contact surfaces. 3D Model
 In single stages superposition with
dynamic loading.
Suction Side
Vane Hook Improvements Fleet Experience
Solution
1. Smooth transition
hook / airfoil
2. Plain (parallel)
hook surfaces
3. Increased hook
width
Old design New design

Compressor
V94.3A / 17 stage Additional Enhancement
for Stage 2 & 4 Fleet Experience
Frequency Tests (Modal Analysis) at Berlin Factory performed for new design.
Sche matic Vie w of Modal Analysis
Stage 4 with new design
Verification of FEA analysis with regard to frequency margin by

modal analysis (natural frequency measurement).

Design
Conceptual Basic
Preparation
Commerciali-
Validation
Perfor mance
M00 M10 M20 M30 M40 M50 M60 M70 M80 M90 M100
Fleet Experience
R0 R1 R2 R3 R4 R5 R6 R7 R8 R9 R10
Reported From Sites

Market Demand: More Operational Flexibility
Increase of green energy production requires
Market Demand
2000: 18 GW 2010: 160 GW 2020: … GW
Operational Flexibility
Source: Global Wind Energy Council, 2010
Improved
Start-up Curve Current
Smart Grids ST+GT
Start-up
Plant Load
loading
Curve
GT+ST
Improvement
parallel
Start-up
GT Hold-time
GT Start-up
Time
More Operational Flexibility - Example
Wet Compression - How it Works Market Demand
Air Intake
Comb.
Compressor Turbine
Chamber
Cooling Air
Evap. Inter Steam power

cooling cooling effect augmentation
effect effect
Efficiency improvement
Siemens Gas Turbine Modernization
Wet Compression Market Demand
Main Facts
 Controlled water injection in front of

the compressor
 Optimized positioning of spray rack and
droplet distribution in the inlet duct
 Optimized droplet size for best
vaporization effect
 Minim ized erosion and corrosion
 OEM* experience to handle large quantities of
demineralized injected water
 GT-Customized: axial thrust compensation, Spider Nozzle
surge protection and controlled combustion
dynam ics
* OEM … Original Equipment Manufacturerx

Siemens Gas Turbine Modernization
Wet Compression Market Demand
Benefit
Power output improvement*
- up to 30 M W on gas turbine SGT5-4000F

- up to 18 M W on gas turbine SGT5-2000E
** Subject to specific technical plant evaluation,
expected values with test tolerance @ ISO
conditions.
References
More than 40 Wet Compression syste ms**
installed on the frame types SGT5-2000E,
SGT6-2000E, SGT6-3000E and W501FC+.
First Wet Compression systems sucessfully

implemented on the fram e type SGT5-4000F.
** As of May 2010

SGT5-4000F / V94.3A Gas Turbine
Market Driver and Benefits
o … neutral
Market Driver Power Efficiency Emission Reliability & Operational Maintenance
Product Increase Increase Reduction Availability Flexibility Cost Reduction
ACC
(Advanced Compressor Coating)
+ + o + o o
ACCSpro (Siemens‘ Advanced
Legend: + … positive
Compressor Cleaning System – + + o + o o
pro)
CMF+
(Compressor Mass Flow ++ o o o o o
Increase)
EVAP Cooler ++ o o o + o
FODS (Foreign Object Detection
System) o o o ++ o o
Fuel Conversion
(according to SIGAMA) o o o o + o
HCO (Hydraulic Clearance
Optimization) + + o o o o
LTE (Lifetime Extension) o o o + o +
TD (Turndown) o + o o ++ o
WetC (Wet Compression) +++ o o o +++ o

Market Driver and Benefits (1)

33MAC o o o ++ + ++
41MAC o o o ++ + ++
ACC
(Advanced Compressor + + o + o o
Coating)
CMF+
(Compressor Mass ++ o o o o o
Flow Increase)
EVAP Cooler ++ o o o + o
FTI
(Firing Temperature ++ + o o o +
Increase)
Fuel Conversion o o o o + o
HR3-Burner o o ++ + o o
o … neutral

Market Driver and Benefits (2)

IGV Modification o o o + o o
LTE
(Lifetime Extension)
o o o + o +
OTC Control
Optimization
o o o o + +
Si3D Stages 1+2 ++ +++ o o + +
Si3D Stages 3+4 ++ ++ o o + +

WetC
(Wet Compression) +++ o o o +++ o
o … neutral

Agenda
1. Frame Portfolio

LTE - additional machine life time
The life of a component is limited!
therefore it is not a question if it fails, but when it fails.
therefore LTE helps to prevent catastrophic failures.
LTE stands for high availability, reliability and

therefore
safety.
LTE can enable the extended life of a
AL:N ECCN: N
component at optimum performance levels

Lifetime Extension
with out
Average overall component risk prior to Lifetime Extension
Average overall component risk with Lifetime Extension End of Design Life
100,000 EOH /
Average overall component risk without Lifetime Extension
3,000 starts
LTE
Potential for increased
Major Inspection * risk of operation
beyond 100,000 EOH /
3,000 starts without
Risk
Lifetime Extension
Lifetime Extension program designed

to help reduce risk of operation
Minor Inspection
* Major Inspections might be executed as a
Equivalent Operating Hours / Starts Hot Gas Inspections, depending on site
specific s or findings

Aging Factors - Aging Effects:
Some common aging mechanisms evaluated at the 100,000 EOH inspection
Compressor Compr. stator II, Burner complete: Combustion Chamber Disk spring stack,
blades & vanes: Diffusor, Radiation •Creep Outer shell Screws, Tile holder:
•Creep liner: •Wet Corrosion •Oxidation, Corrosion •Creep
•Wet corrosion •Creep •Low cycle fatigue •Creeping, Material removal •(Low cycle fatigue)
•Low cycle fatigue •Low cycle fatigue •High cycle fatigue •Low cycle fatigue
•High cycle fatigue •Material removal •High cycle fatigue Housing: • Creep
•Low cycle fatigue
Tie rod nut, cooling air, Tie Rod, middle hollow shaft, Turbine stator: Turbine B&V:
front/rear hollow shaft, Compr./Turbine disks: •Creep •Oxidation, Corrosion
intermediate shaft: •Creep •Low cycle fatigue •Creeping, Material removal
•Low cycle fatigue •Low cycle fatigue
•Creep
•Low cycle fatigue •High cycle fatigue •High cycle fatigue

Siemens Experience with Life Time Extension (LTE) across fleets
Siemens SGT5-4000F / SGT5-2000E Operating Regime
SGT5-40 00F
3500 SGT5-20 00E
LTE
3000
2500
Number Of Starts
2000
1500
1000
500
0
-10.000 10.000 30.000 50.000 70.000 90.000 110.000 130.000 150.000
Equivalent Ope rating Hours

The challenge about comprehensive LTE
Planning – technical aspects
-36 -24 -12 0 12 24

(months before LTE) LTE (months after LTE)
66 74 82 90 100 108 Compressor

116 124
side 133
MO HGPI
MO
1.LTE
LTE Pre-review Replace ment of
• Evaluation Questionnaire limited Components
• Final Outage meeting
• Operation history analyzing MO + LTE
• LTE recomme ndation by unit
• Destructive Inspections
AL:N ECCN: N
specific investigation
• NDT Inspections
• Repairs
• Replace ments
• Evaluation
LTE Experience
Example: Rotor of mature frames
Rotor

Volumetric Re-qualification of Rotor
UT Indication
Ultra Sonic (UT) Inspection of Forged Rotor Components
Highly sensitive Ultrasonic Test inspection method for rotor components

developed and qualified to detect critical internal flaws
Volumetric re-qualification of rotor components in critical areas
LTE Experience
Example: Rotor of mature frames
Results of LTE - NDE Disc Inspection
Inspected GTs
without
indications
79%
Inspected GTs
with indications
21%
Indications = cracks, forging defects, etc. that required further evaluation

LTE summary
Status:
 LTE program derived from R&D program over last
decade and unit experience;
 Experience of +60 LTE`s across frames is adding to
knowledge base & engineering evaluation;
 base LTE experience with mature frames since 2003,
with advanced (A-)frames since 2009;
 Findings confirm evaluation for testing and replacement
of components, especially with units operating under
more severe conditions (fuel, ambient conditions etc.)
Outlook:
 Constant update of component LTE
LTE by SIEMENS will optimize the service life,
reliability and availability of components!

Summary
Siemens Energy provides you the

power to improve the performance of
your gas turbine and your
competitiveness!
 Full range of options
o Power and efficiency increase
o Operational flexibility
o Maintenance cost reduction
o Emission reduction
o Reliability & availability increase
 Gas turbine performance enhancements for
all benefits available.
 Product validation and operational
experience help ensure high reliability.

Thank You
for Your Attention!
Disclaimer
This docum ent 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 ac hievements that m ay be expressed or implied by such forward-
looking statements. For us, particular uncertainties aris e, among others, from changes in general
economic and business conditions, changes in currenc y exchange rates and interest rates,
introduction of c ompeting products or technologies by other companies, lac k of acceptance of new
products or services by custom ers 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 uncertainties m aterialize,
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. Siem ens 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, it's affiliates or their
respective owners.


Innovacin en Servicios en Generacin de Energa Modernizacin - Oliver Neukrantz

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Innovacin en Servicios en Generacin de Energa Modernizacin - Oliver Neukrantz

Uploaded by

Copyright:

Available Formats

Energy - Día de la Innovación

© Siemens AG 2010. All rights reserved.

© Siemens AG 2010. All rights reserved.

More than 700 units in commercial operation worldwide! *

SGTx-4000F (Vx4.3A) SGT5-8000H

Extension of our product portfolio to satisfy customer demands

© Siemens AG 2010. All rights reserved.

• Firing Temperature Increase

170 Units in Commercial Operation 1)

© Siemens AG 2010. All rights reserved.

• HR3 Burner 2003

* Source: Framebook as of June 2010

© Siemens AG 2010. All rights reserved.

© Siemens AG 2010. All rights reserved.

*HGPI = Hot Gas Path Inspection,

25 M AC Concept, 4 kEOH Minor Inspection Interval

Major Major Major LTE

Container Container Container Container Container Container Container Container

Con Container Container

© Siemens AG 2010. All rights reserved.

main locations Engineering Support

Customer Feedback Gate 1 Gate 2 Gate 3 Gate 4 Gate 5

© Siemens AG 2010. All rights re served.

Asses Voice User Group

Drivers for Development

1 Analysis of over 93 units

Generic Hardware Scope

 New igniter design

 Installation during major outage

© Siemens AG 2010. All rights re served.

Site A Outage in September 2008

Site B Outage in January 2009

 Effectiveness of Starting Reliability Package validated.

Ready for Fleet Wide Implementation

© Siemens AG 2010. All rights re served.

Customer Feedback Gate 1 Gate 2 Gate 3 Gate 4 Gate 5

Market Demand Product Planning

© Siemens AG 2010. All rights re served.

• 15-stage compressor with

• 17-stage compressor with

© Siemens AG 2010. All rights re served.

Old design New design

Sche matic Vie w of Modal Analysis

Stage 4 with new design

Verification of FEA analysis with regard to frequency margin by

Customer Feedback Gate 1 Gate 2 Gate 3 Gate 4 Gate 5

Market Demand Product Planning

© Siemens AG 2010. All rights re served.

Increase of green energy production requires

2000: 18 GW 2010: 160 GW 2020: … GW

Evap. Inter Steam power

 Controlled water injection in front of

© Siemens AG 2010. All rights reserved.

- up to 30 M W on gas turbine SGT5-4000F

First Wet Compression systems sucessfully

© Siemens AG 2010. All rights reserved.

LTE (Lifetime Extension) o o o + o +

WetC (Wet Compression) +++ o o o +++ o

Market Driver Power Efficiency Emission Reliability & Operational Maintenance

© Siemens AG 2010. All rights reserved.

Market Driver Power Efficiency Emission Reliability & Operational Maintenance

Si3D Stages 1+2 ++ +++ o o + +

Si3D Stages 3+4 ++ ++ o o + +

© Siemens AG 2010. All rights reserved.