SIEMENS’ MEDIUM SIZE GAS TURBINES CONTINUED …
Transcript of 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
POWER-Gen Europe 2010 Amsterdam Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
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
Page 5 POWER-Gen Europe 2010 Amsterdam Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
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%
Page 6 POWER-Gen Europe 2010 Amsterdam Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
Mechanical Drive 34,100 bhp
Electrical Output 24.8 MW
Efficiency (PG/MD) 34.2%/ 35.1%
Exhaust Mass flow 80.4 kg/s
Exhaust Temperature 543 0C
2rd generations DLE emission:
NOx on gas: < 25 ppmV @15% O2
NOx on liquid: < 42 ppmV @15% O2
SGT-600 first introduced (started) 1986.
DLE introduced 1991.
Total of units sold today is 258
- 147 units in Mechanical Drive (MD) application
- 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
SGT- 600- Key Core Engine Features and Experience, Data - January 2010
Availability: 95,5%Reliability: 98,8%
Page 7 POWER-Gen Europe 2010 Amsterdam Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
Mechanical Drive 42,995 bhp
Electrical Output 31.2 MW
Efficiency (PG/MD) 36.4%/ 37.4 %
Exhaust Mass flow 91 kg/s
Exhaust Temperature 528 0C
3rd generations DLE emission: NOx on gas: <15 ppmV @15% O2NOx on liquid: <42 ppmV @15% O2
SGT-700 first introduced (started) 2004.
DLE standard.
Total of units sold today is 43
- 24 units in Mechanical Drive (MD) application
- 19 in Power Generation (PG)
Total fleet operating hours > 200 000 hours
Fleet leaders:
- PG: > 40 000 hours
- MD: > 10 000 hours
SGT- 700- Key Core Engine Features and Experience, Data - January 2010
Availability: 96,7%Reliability: 99,1%
New rating 31 MWExisting engines can be upgraded
43 units Sold
Page 8 POWER-Gen Europe 2010 Amsterdam Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
Mechanical Drive N/A
Electrical Output (PG) 47 MW
Efficiency (PG) 37.5 %
Exhaust Mass flow 131.5 kg/s
Exhaust Temperature 544 0C
3rd generations DLE emission:
NOx on gas: < 15 ppmV @15% O2
NOx on liquid: < 42 ppmV @15% O2
SGT-800 first introduced (started) 1999.
DLE standard.
Total of units sold today is 109
- All in Power Generation (PG)
Total fleet operating hours > 1 000 000 hours
Fleet leaders:
- PG: > 67 000 hours
SGT- 800- Key Core Engine Features and Experience, Data - January 2010
Availability: 98,0%Reliability: 99,8%
109 units sold
up to Jan.2010
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
Page 10 POWER-Gen Europe 2010 Amsterdam Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
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
Page 11 POWER-Gen Europe 2010 Amsterdam Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
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
Page 12 POWER-Gen Europe 2010 Amsterdam Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
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
Page 13 POWER-Gen Europe 2010 Amsterdam Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
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 )
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
Page 15 POWER-Gen Europe 2010 Amsterdam Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
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
Page 16 POWER-Gen Europe 2010 Amsterdam Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
Current repair status SGT-700- Repairs according to maintenance plan & on condition
Turb blade #1
Honeycomb seals
1st Vane
2nd Vane
Combustion ChamberReady
Under development
Burner
Sealing edge replacement
Comp, recoat abradable rings
SGT-700 repair as a part of Maintenance Program to reduce maintenance cost
Page 17 POWER-Gen Europe 2010 Amsterdam Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
Turb blade #1
Honeycomb seals
Sealing edge replacement
1st Vane 2nd Vane
Combustion ChamberComp, recoat abradable rings
Ready
Under development
Comp, blade & vane recoating
Current repair status SGT-600- Repairs according to maintenance plan & on condition
SGT-600 repair as a part of Maintenance Program to reduce maintenance cost
Page 18 POWER-Gen Europe 2010 Amsterdam Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
Gas collector
Ready
Under development
Fuel injectors
LP & HP comp recoating
Combustor
Flame head
Current repair status SGT-500- Repairs according to maintenance plan & on condition
Repair as a part of Maintenance Program to reduce maintenance cost
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
Page 20 POWER-Gen Europe 2010 Amsterdam Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
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
Page 21 POWER-Gen Europe 2010 Amsterdam Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
Level E + LTA
Compressor turbinevanes # 1 & 2
Compressorturbineblades # 1
Combustionchamber
Power turbineblades # 3
Life Cycle and Maintenance Improvement - Life Cycle extension (SGT-600 example)
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
Page 23 POWER-Gen Europe 2010 Amsterdam Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
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
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
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 C
Level B
Level A
OperationMaintenance
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
Page 24 POWER-Gen Europe 2010 Amsterdam Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
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
Page 25 POWER-Gen Europe 2010 Amsterdam Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
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
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
POWER-Gen Europe 2010 Amsterdam Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
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.
Page 28 POWER-Gen Europe 2010 Amsterdam Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
Thank you for your attention!