vgb conference gas turbines and operation of gas turbines 2013

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VGB ConferenceGas Turbines and

Operation of Gas Turbines 2013

11-12 of June 2013, Friedrichshafen, Germany

Gas Turbine Performance and Maintenance Continuous Improvement

Dr. V. Navrotsky,

Siemens Industrial Turbomachinery ABFinspong, Sweden

VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden Page 2

1. Introduction

2. Development History & Operating experience

3. Emission reduction

4. Extension of Engine life cycle

5. Maintenance Down Time reduction

6. Maintenance cost reduction

7. Operation Improvement

8. Ongoing SGT-600 Upgrades and Improvements

9. Summary

Outline

VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden

SGT5-4000F

SGT6-5000F

SGT5-2000E

SGT6-2000E

SGT-800

SGT-700

SGT-600

SGT-500

SGT-400

SGT-200

SGT5-8000H

SGT-100 5

287

198

168

47/50

31/33

25

19

13

7

113

375

8SGT-300Industr

ial T

urb

ines

Utilit

y T

urb

ines

Siemens Industrial gas turbine range

SGT6-8000H 266

SGT-750 36

(MWe)

Siemens offer a wide power range of Gas Turbines for Industrial and O&G markets


Two shaft Gas Turbine10 stage compressor (PR=14)

Two stage compressor turbine

Two stage power turbine

SGT-600 Latest Design FeaturesGeneral Design

Welded compressor rotor,

Two variable guide vanes,

Two bleeds after stage 2 and 5,

All blades are coated (titanium blade 1)

Abradable coating on all stator rings

2:nd generation Dry Low Emission Comb.

Integrated by-pass systemThe design for PG is the sameas for a MD


Outline

1. Introduction








9. Summary


DLE introduced 1991Total of units sold today is 300+

66% in Mechanical Drive (MD) application34% in Power Generation (PG)

Total fleet operating hours > 7+ million hours5+ million of those on DLE

Fleet leaders:> 160 000 hours> 3 600 starts

Fleet details

The SGT-600 evolution

SGT- 600Key Core Engine Features and Experience, Data - March 2013

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 C

2rd generations DLE emission:

NOx on gas: < 25 ppmV @15% O2

NOx on liquid: < 42 ppmV @15% O2

Technical details

SGT-600 first introduced 1986

1975 1980 1985 1990 1995 2000 2005

Prototype testing 300+ units by SiemensTransfer4 units by

Sulzer

#1 Package

DLE

Uprating

#2 Package FloaterPackage

Sulzer Escher Wyss (CH)

Transfer SEW to ABB STAL AB* (SE)

Siemens

SGT-600 Specification

Reliability: 99.5% Availability: 96.5%


Outline

1. Introduction








9. Summary


MGT Combustor technologies2nd 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)


Outline

1. Introduction








9. Summary


Life Cycle Extension ProgramLife Cycle extension LTA / LTE

Level E + LTA

Operation

Maintenance

Level A

Level B

Level C

Level D

LTE

10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160

EOH x 1000

SGT-600 Maintenance Schedule with LTA & LTE

Life Time Extension

120,000 EOH level C inspection +:Recommended replacements as

agreed with customer

Upgrade packages as agreed with

customer

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 operationBeyond 120,000 EOH

Tailored scope of repair & replacement parts for LTE


Compressor turbinevanes # 1 & 2

Compressorturbineblades # 1

Combustionchamber

Power turbineblades # 3

Life Cycle Extension Life Cycle extension = LTA + LTE

Tailored scope of repair & replacement parts for LTE


Blade grooves

Centre holes Blade grooves

Balancing holes

Balancing holes

Centre and bolt holes

Stop holes

Internal radius transitions

Replica tests

Weld examination

Life Cycle Extension Rotor condition examination


Outline

1. Introduction








9. Summary


Extension of inspection intervals from

20 000 EOH extended to 30 000 EOH by

means of improvements in the lifetime of major components

Advantage of Remote diagnostic service

Improvements of maintenance tools

Maintenance Down Time reduction

Extension of Maintenance Intervals -> 3 overhauls instead of 5

10 20 30 40 50 60 70 80 90 100 110 120

Level C

Level B

Level A

OperationMaintenance

Eq. Op. Hrs x 1000

Major Overhaul

Hot Section Inspection

Borescope

5

2 =

3in

sp

ectio

ns

The Extension of Maintenance Intervals can improve the availability by up to ~ 1 %


.

SGT-600 Maintenance Down time reductionDevelopment of Maintenance tools

SGT-600 Maintainability improvement results in reduction of Maintenance duration and cost

Compressor blade

dismantling tool Gearbox tool Gas Generator

extraction tool

reduces down time

improves safety

reduces down time

simplifies work

improves safety

25% inspection time

reduction

80% blades saving

improves safety


Outline

1. Introduction








9. Summary


Repair is primary done to support the maintenance plan. Current repair scope included into Maintenance Plan:

Combustor repair DLE & Conventional

Turbine GV #1 repair

Turbine GV #2 repair

Current scope of repair on condition:Compressor abradable ring recoating

Turbine blade #1 repair

Rotor seal edge repair

Honeycomb seals #1, #2 & #3 repair

Compressor blade & vane recoating

Siemens invest significantly into R&D development to support further increase

of repair yield and reduce repair cost

Current repair status SGT-600Repairs according to maintenance plan & on condition


Turb blade #1

Honeycomb seals

Sealing edge replacement

1st Vane 2nd Vane

Combustion Chamber

Comp, recoat abradable rings

Comp, blade &

vane recoating

Current repair status SGT-600Repairs according to maintenance plan & on condition

SGT-600 repair as a part of Maintenance Program to reduce maintenance cost


Hot gas path components

Closer look at combustor and turbine parts going for repair

Combustor

Blade #1

Vane #1

Vane #2

Honeycomb 1

Honeycomb 2

Honeycomb 3


DLE Combustor repair

Typical repair actions:

1. Incoming inspection & assessment

2. Cut combustor according to dwg.

3. Strip coating by grit blasting

4. Inspect heat shield and liner condition

5. Adjust, weld repair and replace parts

6. Recoat heat shield, inner & outer liner

7. Assemble by welding

Typical repair options:

A. Replacement of Heat Shield

B. Replacement of inner and outer

liner

C. Weld repair of burner cone

D. Replacement of by pass sleeves

E. Cleaning of carbonized oil in

burners

Only part of available repair

options are required


Turbine GV #1

Oxidation of

parent material

Crack in trailing edge


Incoming inspection & registration

Strip coating, chemical

Inspect & assessment

Blend to remove oxidation

Solution heat treatment

Weld repair as required

Floride Ion Cleaning (FIC)

Braze repair as required

Restore dimensions and gas path

shape

Recoat according to spec

Final insp. incl flow properties


Turbine GV #2

Crack in key slot

Oxidation of sealing fins


Incoming inspection and registration

Strip coating, chemical

Inspect and assessment

Blend to remove oxidation

Solution heat treatment

Weld repair as required

Floride Ion Cleaning (FIC)

Braze repair as required

Restore dimensions and shape

Recoat according to spec

Final insp. Incl. flow properties


Honeycomb repair


1. Incoming inspection and registration

2. Clean part by light grit blast

3. Remove old HC

4. Inspect and assessment

5. Braze new HC in place

6. Machine HC to final height

7. Final inspection


Compressor abradable ring repair


1. Incoming inspection and registration

2. Clean part by light grit blast

3. Remove old coating by machining

4. Inspect

5. Apply Nickel plating

6. Apply abradable coating

7. Machine to final dimension

8. Final inspection


Repair technology development

To offer different repairs at reasonable prices Siemens is continuously developing and updating different repair technologies and methods.

Laser Cladding Technology

Laser Sintering

Non-destructive InspectionsInfrared Thermography

3D X-ray Tomography


Outline

1. Introduction








9. Summary

VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden 27

Expert

Network

Team

Offline Diagnostics

DiagnosticsCenters

Power Plant

Advanced diagnostic

tools & techniques for:

Monitoring of engine conditions

Data collection / processing

Analysis of limit values

& deviation from

normal behaviourWo

rld

wid

e S

iem

en

s

Ne

two

rk f

or

Da

ta E

xch

an

ge

Reports

Info

Access

Monitoring

Analysis

Engineering Know-how:

Interpretation & Diagnostics

Data assessment

Development of

recommendations for future

operations, repairs and / or

modernizations

Online DiagnosticsOnline Diagnostics

Operating Data +

Specialty Monitor

Customer Relationship Management

Operation Improvement & optimization From Data collection & analysis to Customer Value Generation


Outline

1. Introduction








9. Summary


.

Ongoing SGT-600 Upgrades and Modificationsupports continuous product and services improvement

1200

34 EOH

15 ppm

32.4 %MD

19.8 MWMD

TargetBaselineDescription

600Increased cycle based TBO, without reduced T7-limit at hot ambient conditions.

30 EOHIncreased time based TBO, without reduced T7-limit at hot ambient conditions.

24,4-30 ppm

AEV: Reduced NOx Emissions at 100%-50% load (gas fuel)

31.9 %MDIncreased efficiency at hot ambient temperatures, 45OC

18.3 MWMDIncreased power at hot ambient temperatures, 45OC

Focus on further Emission & Downtime reduction, Flexible operation & life extension (including cyclic life)

36 60 52 6027 60 52 60


Outline

1. Introduction








9. Summary


Summary

Continuous Improvement of SGT-600 is part of Siemens long-term product development strategy

SGT-600 fleet demonstrates high reliability & availability

Latest modifications of SGT-600 enable: extension of engine life-cycle beyond 120,000 EOHextension of maintenance intervals from 20,000 to 30,000 EOH

Extended maintenance intervals from 20,000 to 30,000 EOH enable availability increase by about 1% p.p.

Currently ongoing SGT-600 upgrades will support flexible operation and opportunity for further Life Cycle Cost reduction


Disclaimer

This document 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 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

forward-looking 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 this document are the property of Siemens AG, it's affiliates or their respective owners.


Operation with varying Wobbe-index (WI)

78

Medium Calorific Value (MCV)

10 20 40 50 60 7030

Normal Pipeline NG High Calorific Value (HCV)

Wobbe Index (MJ/Nm)

Low Calorific Value (LCV)

40 55

Fully released; DLE

Sales approved case by case

25

Fully released; Conventional

35

Increased request for operation on gas with varying energy content

Previously handled by adding WI-meter to the governing system

Special configuration of the control system gives the possibility to use the GT

itself as WI-meter using only standard instrumentation and results in:

Faster and more accurate monitoring of the WI

Improved reliability

Reduced cost of installations operating with varying WI


Repair as part of maintenance concept

120 EOHNew & Clean0 EOH

Level B20 EOH

Level C40 EOH

Level D60 EOH

Level E80 EOH

Level B100 EOH

CT Blade 1, Set #1 NEW

CT Blade 1, Set #2

CT Blade 1, Set #3

NEW

CT Blade 2, Set #1 NEW

CT Blade 2, Set #2

PT Blade 3, Set #1 NEW

PT Blade 3, Set #2 NEW

Comb. Ch., Set #1 NEW RECONDITIONED

Comb. Ch., Set #2 NEW

RECONDITIONED

RECONDITIONED RECONDITIONED

CT Vane 1, Set #1 NEW

NEWCT Vane 1, Set #2

RECONDITIONED

NEWCT Vane 1, Set #3

RECONDITIONED

RECONDITIONED



NEW

NEW

RECONDITIONED

RECONDITIOND

NEWPT Blade 3, Set #3


Current repair status SGT-600- Repairs technology details and Repair Suppliers

SGT-800 repair as a part of Maintenance Program to reduce maintenance cost

Repair not qualifiedHeat shield

Repair not qualifiedTurbine blade 2

PAS, IrelandN/APtAlYesYesYesTurbine Vane 2

Turbocoating, ItalyAPSPtAlYesN/AYesTurbine Blade 1

PAS, IrelandN/APtAlYesYesYesTurbine Vane 1

Only applicable for conv.

burners, Unison, UKN/AN/AN/AN/AYes, replace tipBurners

In house / Volvo AeroAPSAPS bond coatYesN/AYesCombustor

Recotech, SWN/AMetco 307YesN/ANoAbradable rings

Seals replaced by

caulkingN/AN/AN/AN/AN/ARotor seals

Repair in qualification

CCRS, UKN/AV900YesNoNoComp. vanes

Repair in qualification

CCRS, UKN/AV900YesN/ANoComp. blades

SuppliersTBC typeCoating typeStripingBraze repWeld repairComponent

vgb conference gas turbines and operation of gas turbines 2013

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