SGT5-8000H / Irsching 4 H Class Performance beyond F Class Flexibility - more than 10.000 EOH Reliable Operation - now in Commercial Service, daily start-stop
October 2011, Kuala Lumpur Frank Haffner Siemens Energy © Siemens AG 2010
It’s all about Energy!
SGT-8000H – Designed for Highest Efficiency in Combined Cycle
Irsching IV Power Plant: Test and Validation
Combined Cycle Plant Design
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© Siemens AG 2011
Scopes of supply adapted to customer needs Market Requirements High power and efficiency Flexibility (e.g. fuel, operation) High reliability and availability Optimized construction Low risk Defined investment
Optimized power plant concept – Siemens Reference Power Plant (2+1, 1+1) or Turbine Packages Turnkey
SCC-PAC
e.g. SCC5-4000F 1S
IPPs and Utilities
EPCs
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SGT-PAC
Architect Engineers
© Siemens AG 2011
Siemens Fossil Power: Concentrate on the core components first
Water Pretreatment
Fuel Oil Storage
Water Treatment HRSG HV Switchgear
Cooling Tower Site
Condenser Water Steam Cycle
HBD
GT
I&C
Generator ST Gas Electrical Preheating
Machine House Arrangement Building Facilities Fuel Transfer
Water Supply Civil
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© Siemens AG 2011
Evolution of Siemens Combined Cycle Technology 1991 SGT5-2000E
1996
2011
2008
2015
SGT5-4000F
SGT5-4000F
SGT5-8000H
SGT5-8000H:
(Intro)
(latest upgrade)
(Intro)
(next steps)
> 50%
> 56%
> 58,5%
> 60%
> 61,5%
CC efficiency*
CC efficiency*
CC efficiency*
CC efficiency*
CC efficiency*
CCPP Killingholme (2x1) 2 x 450 MW
CCPP Didcot B (2x1) 2 x 705 MW
CCPP Mainz (1x1) 405 MW
CCPP Irsching 4 (1S) 578 MW
CCPP SCC5-8000H (1S) > 600 MW
525 °C / 80 bar 2PR-non RH
540 °C / 110 bar 3PR-RH
565 °C / 125 bar 3PR-RH
600°C / 170 bar 3PR-RH, Benson
t.b.d.
10 % points increase in efficiency over approx. 20 years * at ISO conditions conditions
Future © Siemens AG 2011
Large-scale Siemens Gas Turbine Portfolio for 50 and 60 Hz SGT5-8000H
375 MW
SGT5-4000F
292 MW
SGT6-8000H
274 MW 206 MW
SGT6-5000F SGT6-4000F
187 MW 168 MW
SGT5-2000E SGT6-2000E
113 MW
SGT5-8000H
SGT6-8000H
04/2007
01/2011
Direct scale 1 / 1,2 (50 / 60 Hz)
© Siemens AG 2011
SGTx-8000H Designed for Highest Efficiency in Combined Cycle
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© Siemens AG 2011
Key data
SCC5-8000H 1S output
570 MW
GT output
375 MW
GT efficiency
40%
GT heat rate
< 9000 kJ/kWh
Fuel
Grid frequency
Weight
444 t
Length
13,2 m
Height
5,0 m
Nat. gas, fuel oil 50 Hz
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© Siemens AG 2011
SGT5-8000H designed for over 60% efficiency in combined cycle
High cycling capability due to advanced blade cooling system
Four stage turbine with advanced materials and thermal barrier coating
Advanced Ultra Low NOx (ULN) combustion system Evolutionary 3Dcompressor blading
> 60% Combined Cycle efficiency
Proven rotor design, free radial thermal expansion and central tie rod
Integrated combined cycle process for economy and low emissions E F PR /
© Siemens AG 2011
SGT5&6-8000H Advanced Engine Concept Siemens Design
Westinghouse Design
Single tie bolt
Turbine cylinder
Front hollow shaft
Turbine features
Compr. stat. design
Turbine vane carrier
Bearings
Turbine diffuser
Exit housing
Compressor cylinder
Harmonized Compressor
ULN can-annular combustion system
Secondary Air System
“on-board” air cooling concept for > 60% CC efficiency combined with highest operational flexibility © Siemens AG 2011
Agenda
GT Design and Main Features
Rotor / Casings
Compressor
Combustion
Turbine, HCO E F PR /
© Siemens AG 2011
SGT5-8000H – robust rotor and casing design
Rotor and Casing
1) Status: 2009-12-16 SALT, 50Hz
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Disk-type hollow-shaft rotor
Disks axially fixed by central tie rod
Compressor and Turbine Disks interlocked and centered by Hirth coupling serrations ⇒ excellent fleet experience over decades for this design exceeding 16,500,00 EOHs and 757 GT engines build 1)
Casing, using proven features from existing fleet
© Siemens AG 2011
The Rotor is based on the experience and success of the proven central tie bolt system
Proven design Conventional steel alloy discs
Turbine disc with Hirth serrations
Rotor with single tie bolt
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© Siemens AG 2011
Agenda
GT Design and Main Features
Rotor and Casings
Compressor
Combustion
Turbine, HCO E F PR /
© Siemens AG 2011
Compressor designed for robustness, increased turndown and reduced outage times
Rotor and Casing
Mass flow 820 kg/s
Pressure ratio of 19.2
13 stages
Cantilevered vanes for rows 5 - 13
4 variable guide vanes to improve part load performance
Designed for Hydraulic Clearance Optimization (HCO)
Uncoated blades and vanes
All
CDA – Controlled Diffusion Airfoil
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blades replaceable without rotor lift
HPA – High Pressure Airfoil
© Siemens AG 2011
Agenda
GT Design and Main Features
Rotor and Casings
Compressor
Combustion
Turbine, HCO E F PR /
© Siemens AG 2011
Combustion – ULN applied to SGT5-8000H to achieve higher combustion temperatures reliably
Ultra Low Nox Combustion System
1) Status: 2008 Aug.
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ULN Features
Proven low risk Platform Combustion System (same burners in 50Hz and 60Hz version)
16 baskets with air cooled transitions
Capability to achieve high combustion and turbine inlet temperatures
Large experience with can annular systems
> 400 GT units with can-annular system and with more than 12,000,000 OH 1)
Fuel flexibility (gas / liquid fuels)
© Siemens AG 2011
Combustor design – reliable low emission combustion system
Main Nozzles (A / B stages) B
Premix C-stage
A
B
Flow sleeve
Basket
A A/B stages
A
B A
B
Premix Pilot Nozzle
D stage
C stage
Pilot diffusion
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© Siemens AG 2011
Agenda
GT Design and Main Features
Rotor and Casings
Compressor
Combustion
Turbine, HCO E F PR /
© Siemens AG 2011
Siemens SGT5-8000H – efficient air-cooled turbine
Turbine part
Four stage turbine for high efficiency stage loadings with aerodynamic clocking of first 3 blade rows.
Air-cooled turbine airfoils for assured cooling in operation & plant flexibility.
Directionally solidified R1 blade & new TBC systems for increased TIT. No single crystal blades.
Innovative secondary air system from aero engine technology for efficient cooling air delivery and utilization.
First stage blade and vane removable through the combustor without cover lift
Conical flow path for HCO.
Application of proven base materials combined with new technologies for higher efficiency E F PR /
© Siemens AG 2011
SGT-8000H Extraction Overview E1 E2 E3
I1
Extraction
S2
S1
Type
E1
external
E2
external
E3
external
I1
internal
S1
internal
S2
internal
Secondary Air System
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© Siemens AG 2011
SGT-8000H:Secondary Air System (SAS)
E2
E1
E3 S2
S1 I1 S1; S2: internal extraction
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© Siemens AG 2011
Hydraulic clearance optimization (HCO) for increased performance and power output
Rotor shift through HCO Design Features
Hydraulic rotor shift in axial position by pistons behind the compressor axial bearing Conical flow path geometry results in reduced blade tip clearances Clearances are designed for hot restart and can be reduced during operation (thermal stability) Provides clearance margin during transient startup/shutdown operation Fail safe design E F PR /
© Siemens AG 2011
Serviceability – a key design factor to assure optimized outage time and higher availability
TVC roll out/roll in capability
Roll out/in capability of the turbine vane carrier enables exchange of stationary turbine hardware without rotor lift
Sequence and tooling successfully tested during final assembly and prototype test
Removable compressor blades
Removable turbine blades and vanes
All
All
rotating blades replaceable without rotor de-stack or lift.
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blades removable without rotor lift
Vane 1 and blade 1 removable through the combustion chamber
Blade 4 removable to the exhaust end © Siemens AG 2011
Irsching IV Power Plant: Test and Validation E F PR /
© Siemens AG 2011
Process quality is the basis for products creating maximum value for our customers Product Development Process
Strategic Product Planning
Product Strategy
Sales Preparation
Design
Product & Development Planning, Tech. Acquisition
Conceptual Design
Commercialization Planning
Basic Design
Design Implementation Final Design & Procurement
Manufacturing & Assembly
Validation
Erection, Install., Commissioning & Trial Operation
Product Monitoring & Validation
Parts testing
Casting blades and vanes Materials, coatings Manufacturing trials, etc. Stress, strain verification
Component testing
Combustion system rig test Cover plate rig test Mock up
Prototype CC field operation
System testing
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Compressor test & Combustion system test at test bed Berlin
© Siemens AG 2011
Matrixed, multi-location team structure to integrate Siemens experts worldwide Development Team
Berlin, Germany
Manufacturing
Erlangen, Germany
Program Mgmt. Engine Testing Plant Design
Jupiter, FL, USA
Mühlheim, Germany
Compressor
Engine Integration
Orlando, FL, USA
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Blades Vanes Secondary air
Turbine Combustion System
© Siemens AG 2011
Process quality is the basis for products creating maximum value for our customers Product Development Process
Strategic Product Planning
Product Strategy
Sales Preparation
Design
Product & Development Planning, Tech. Acquisition
Conceptual Design
Commercialization Planning
Basic Design
Design Implementation Final Design & Procurement
Parts testing
Component testing
Erection, Install., Commissioning & Trial Operation
Product Monitoring & Validation
Prototype GT field testing
Casting blades and vanes Materials, coatings Manufacturing trials, etc. Stress, strain verification
Manufacturing & Assembly
Validation
Combustion system rig test Cover plate rig test Mock up
Prototype CC field operation
System testing
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Compressor test & Combustion system test at test bed Berlin
© Siemens AG 2011
Over 2800 additional sensors
Irsching Test Center
Additional sensors
DYNAC Vissio Clients 1&2
EDAS-DR Clients 1...5
DYNAC Station 1-7
Over 2800 sensors measured: Temperatures Pressures Strains Acceleration Clearances Vibrations
BDAS Data Server
Mühlheim
shared
VLAN Mühlheim
EDAS-DS Station 1-5 Test Instrumentation Router
Theme Online Server
shared
Irshing Server BDAS Data Theme Online and BDAS data Clients 1...n with access to CAT services
Encryption shared Irshing Server Theme Online
shared
shared DYNAC Vissio Clients 1&2
SNX Telekom Router
EDAS-DR Clients 1...3
shared shared shared BDAS Data Server
Orlando
Irsching Site Office
shared
VLAN Orlando
Theme Online Server
Telekom Router
Theme Online and BDAS data Clients 1...n with access to CAT services shared
Irshing CAT Server
DYNAC Vissio Clients 1...3 Site Router
Jupiter
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shared
VLAN Jupiter
Theme Online and BDAS data Clients 1...n with access to CAT services
© Siemens AG 2011
Time consuming thermal paint test .... Scope: Major Hot Gas Parts
Vane Carrier
TB 1
Basket Transition Vane 1 Vane 2 Vane 3 Blade 1 Blade 2 Blade 3 Blade 4 Ring Segment 3
(2) (2) (12) (6) (2) (6) (6) (6) (4) (2)
8 weeks for installation (outage)
1 hour operation, straight start
10 min. base load
6 weeks to remove tested parts
TB 2 E F PR /
© Siemens AG 2011
...successfully performed, providing detailed temperature pictures.
397 MW
TB 4 Straight loading to base load required, otherwise results not representative
Vane 1 ID E F PR /
Basket © Siemens AG 2011
Irsching Test Experience & Objectives 1600 1500
Approximate Total Hours
Demonstration of engine integrity through endurance operation
1400 1300 1200
Approximate Baseload Hours
1100
s 1000 r u o 900 H g 800 n i t a 700 r e p 600 O
Verification of individual component performance and engine operation characteristics
500 400 300 200 100 0 20090228
20090330
20090430
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20090530
20090630
20090730
20090830
© Siemens AG 2011
Endurance Test Phase Main Purpose
Collect further mid-long term operating experience, starts and hours, under semicommercial conditions
Test sensor data will still be recorded, however test requirements are no longer prime focus
Confirmation of „readyness for commercial service“, based on load regime required by grid operator
Operate by staff w/o special qualification (other than standard GT O&M experience)
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© Siemens AG 2011
SGT5-8000H - significant operational experience +
Successful cold & hot commissioning
+
Part load and base load operation
+
Performance and emissions demonstrated
+
HCO and fuel preheat experience
+
Gained outage experience regarding burner exchange, bearing lift, cover lift TVC roll-in/out
+
Inspection experience on all components
+
High start up reliability
+
Start-up gradients up to 35 MW/min
+
Frequency Range 47,5 – 51,5 Hz demonstrated
+
Load rejection capability
+
Ignition and Start-Up optimization
+
Grid Code
+
Thermal Paint Test
+
Endurance Run (1143 OH)
Operating Data Test days
122
Starts
174
Operation hours
1525
h
OHs > 50% BL
1404
h
Full load OHs
1243
h
470.000
MWh
Power generated
Gas consumption 122.220.000
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Nm³
© Siemens AG 2011
Proven efficiency and output – proven economic advantages Voice of the customer: E.ON Energie AG, Germany
Bernhard Fischer Member of the Board of Management E.ON Energie AG, Germany
“
In actual operation, the SGT5-8000H has more than met our high expectations: During roughly 1,200 hours of testing in Irsching, Block 4, we were able to experience the performance of the world’s most efficient gas turbine for ourselves. Expansion is currently under way to a combined cycle power plant. With its commissioning in the year 2011, it will similarly set new standards when it comes to efficiency and output.
„
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© Siemens AG 2011
Combined Cycle Plant Design
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© Siemens AG 2011
SGT5/6-8000H Product Line Performance and Configuration Overview
SGT-PAC 8000H
SCC-PAC 8000H 1S
SCC-PAC 8000H 2x1
SCC-PAC 8000H 3x1
50 Hz
60 Hz
375 MW
274 MW
40 %
40 %
570 MW
410 MW
> 60 %
> 60 %
1.145 MW
824 MW
> 60 %
> 60 %
--
1.236 MW
--
> 60 %
SGT5/6-8000H
SCC5/6-8000H 1S
at ISO conditions
SCC5/6-8000H 2x1 © Siemens AG 2011
SCC5-8000H 1S Single Shaft Arrangement
SST5-5000 (600°C)
Condenser
HRSG/Benson, 3P/RH 600°C/170 bar
SSS Clutch SGen5-3000W Lube oil system E F PR /
SGT5-8000H © Siemens AG 2011
Single Shaft Arrangement
Gas Turbine
Generator
Journal Bearing
Excitation
Journal Bearings
Journal Thrust-Bearing Thermal Growth
Clutch
Steam Turbine
Journal Bearings
Journal Thrust-Bearing Thermal Growth Thermal Compensation within Clutch
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© Siemens AG 2011
Multi Shaft Arrangement 8000Hbased on 4000F experience
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© Siemens AG 2011
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© Siemens AG 2011
Customer Benefit – SCC5-8000H 1S Start-up Curves
Start-up Cases
Start-up Time Definition ~40 min 1)
Advanced FACY outage after <8h
~100 min 1)
Warm Start
outage after <64h
Cold Start
outage after <120h ~150 min 1)
Plant Start-up Time begins with ignition of GT and is completed with GT at IGV base load position (position >98%) as well as HP and IP/HRH bypass station closed.
Warm start curve
GT1 Speed (%)
1) expected values
GT1 Load (%)
ST Speed (%)
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ST Load (%)
Plan Load (%)
© Siemens AG 2011
Customer Benefit – SCC5-8000H 1S Highest efficiency
∆ y c n e i c i f f E s s o r G C C
50
Eff. = ~1.5%-Points
SCC5-8000H 1S
SCC5-4000F 1S
60
70
80
90
100
CC Re. Power (%)
Highest performance in base and part load. E F PR /
© Siemens AG 2011
Irsching Units 1 - 5, as of July 2011 Unit 5 4000F
Unit 4 8000H
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Unit 1 – 3 convent. ST‘s
© Siemens AG 2011
SGT5-8000H / Irsching 4 Operational Status, as of Oct. 04, 2011
Phase I GT Testing
Phase II Combined Cycle
Starts Operating hrs Dynamic hrs
85 1525 1990
168* 2663 1639
Sub Total
4365
5982**
Grand Total
appr. 10.300 EOH
* 98,2 % starting reliability, ** 99,8% operating reliability since PAC
© Siemens AG 2011
Irsching 4, as of Sept. 2011 Plant in Commercial Operation on Schedule 08.01.2011 1st Re-fire after CC extension 24.02.2011 First Steam Admission to ST 27.02.2011 First CC Baseload (>550 MW) 06.05.2011 World Record Test Run 11.05.2011 Customer Performance Test 16.05.2011 Start of Reliability Run 22.07.2011 Commercial Operation Daily start and stop Over 10.000 EOH in total, incl. GT testing
© Siemens AG 2011
SGT5-8000H / SCC5-8000H The answer to market and customer requirements
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H Class Performance SGT5-8000H: 375 MW / 40 % SCC5-8000H 1S: 570 MW / > 60%
Reduced Emissions 25 ppm NOx, 10 ppm CO, 330 g/kWh CO2
Improved Operational Flexibilty 15 and 35 MW/min. GT loading 500 MW in < 30 min. plant hot start
High Reliability and Availability
Resulting in Low Life Cycle Costs
© Siemens AG 2011
SCC5-8000H 1S / Irsching 4 World Record Runs, 06.05.2011
Promised and Delivered !
*1 Irsching Site Conditions: Ambient temp. 9°C, pressure 973mbar, rel. Humidity 81%, cooling water 10°C
© Siemens AG 2011
Siemens Combined Cycle Power Plant portfolio 50Hz GT and corresponding CCPP configuration SGT5-8000H
50 Hz GT
375
SGT5-4000F SGT5-2000E
292 168
570
SCC5-8000H 1S SCC5-8000H 2x1
50 Hz CCPP
1.242 434
SCC5-4000F 1S
429
SCC5-4000F 1S SCC5-4000F 2x1
Cold Climate
832
Warm Climate Warm Climate
© Siemens AG 2011
