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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
Energy Sector
Its all about Energy!

SGT-8000H
Designed for Highest Efficiency in Combined Cycle

Irsching IV Power Plant: Test and Validation

Combined Cycle Plant Design

E F PR / Siemens AG 2011
Page 2 Vers. hf; 16.10.2011 frank.haffner@siemens.com Energy Sector
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 SGT-PAC


e.g. SCC5-4000F 1S

IPPs and Utilities EPCs Architect Engineers

E F PR / Siemens AG 2011
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Siemens Fossil Power:
Concentrate on the core components first

Water Fuel Oil


Pretreatment Storage
Water
Treatment
HRSG
HV
Condenser
Switch-
gear
Water HBD I&C
Steam GT
Cooling
Cycle Generator
Tower ST
Gas Electrical
Site Preheating
Machine
House
Building Arrangement
Facilities

Fuel Water
Transfer Supply
Civil

E F PR / Siemens AG 2011
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Evolution of Siemens Combined Cycle Technology

1991 1996 2008 2011 2015


SGT5-2000E 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 CCPP CCPP CCPP CCPP


Killingholme (2x1) Didcot B (2x1) Mainz (1x1) Irsching 4 (1S) SCC5-8000H (1S)
2 x 450 MW 2 x 705 MW 405 MW 578 MW > 600 MW
525 C / 80 bar 540 C / 110 bar 565 C / 125 bar 600C / 170 bar t.b.d.
2PR-non RH 3PR-RH 3PR-RH 3PR-RH, Benson

10 % points increase in efficiency over approx. 20 years Future


* at ISO conditions Siemens AG 2011
Page 5 8000H / Irsching 4 Sales INFO Energy Sector
Large-scale Siemens Gas Turbine Portfolio
for 50 and 60 Hz

SGT5-8000H 375 MW

SGT5-4000F 292 MW

SGT6-8000H 274 MW

SGT6-5000F 206 MW

SGT6-4000F 187 MW

SGT5-2000E 168 MW

SGT6-2000E 113 MW

SGT5-8000H SGT6-8000H
04/2007 01/2011

Direct scale
1 / 1,2
(50 / 60 Hz)

Siemens AG 2011
Page 6 8000H / Irsching 4 Sales INFO Energy Sector
SGTx-8000H
Designed for Highest Efficiency
in Combined Cycle

E F PR / Siemens AG 2011
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Key data

SCC5-8000H 1S output 570 MW

GT output 375 MW

GT efficiency 40%

GT heat rate < 9000 kJ/kWh

Fuel Nat. gas, fuel oil

Grid frequency 50 Hz

Weight 444 t

Length 13,2 m

Height 5,0 m

E F PR / Siemens AG 2011
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SGT5-8000H
designed for over 60% efficiency in combined cycle

High cycling capability due to Four stage turbine with


advanced blade cooling system advanced materials and
thermal barrier coating

Advanced
Ultra Low NOx (ULN)
combustion system

Evolutionary 3D- > 60% Combined


compressor blading Cycle efficiency

Proven rotor design, Integrated combined


free radial thermal cycle process for
expansion and economy and low
central tie rod emissions

E F PR / Siemens AG 2011
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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

ULN can-annular Secondary Air


Harmonized combustion system System
Compressor

on-board air cooling concept for


> 60% CC efficiency combined with highest operational flexibility
Siemens AG 2011
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Agenda

GT Design and Main Features

Rotor / Casings

Compressor

Combustion

Turbine, HCO

E F PR / Siemens AG 2011
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SGT5-8000H robust rotor and casing design

Rotor and Casing

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

1) Status: 2009-12-16 SALT, 50Hz E F PR / Siemens AG 2011


Page 12 Vers. hf; 16.10.2011 frank.haffner@siemens.com Energy Sector
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


Rotor with single tie bolt
Hirth serrations

E F PR / Siemens AG 2011
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Agenda

GT Design and Main Features

Rotor and Casings

Compressor

Combustion

Turbine, HCO

E F PR / Siemens AG 2011
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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 blades replaceable without rotor lift

CDA Controlled Diffusion Airfoil E F PR / HPA High Pressure Airfoil Siemens AG 2011
Page 15 Vers. hf; 16.10.2011 frank.haffner@siemens.com Energy Sector
Agenda

GT Design and Main Features

Rotor and Casings

Compressor

Combustion

Turbine, HCO

E F PR / Siemens AG 2011
Page 16 Vers. hf; 16.10.2011 frank.haffner@siemens.com Energy Sector
Combustion ULN applied to SGT5-8000H
to achieve higher combustion temperatures reliably

Ultra Low Nox Combustion System 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)

1) Status: 2008 Aug. E F PR / Siemens AG 2011


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Combustor design
reliable low emission combustion system

Main Nozzles (A / B stages) Premix C-stage

B A Flow sleeve Basket

B
A
A/B stages

A B

A B

Premix Pilot Nozzle


C stage

D stage Pilot diffusion

E F PR / Siemens AG 2011
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Agenda

GT Design and Main Features

Rotor and Casings

Compressor

Combustion

Turbine, HCO

E F PR / Siemens AG 2011
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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
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SGT-8000H Extraction Overview
E1 E2 E3 S2

I1 S1

Extraction Type
E1 external
E2 external Secondary Air System
E3 external
I1 internal
S1 internal
S2 internal
E F PR / Siemens AG 2011
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SGT-8000H:Secondary Air System (SAS)

E2 E1
E3
S2

S1

I1
S1; S2: internal extraction

E F PR / Siemens AG 2011
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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
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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 rotating blades replaceable without All blades removable without rotor lift
rotor de-stack or lift. Vane 1 and blade 1 removable through
the combustion chamber
Blade 4 removable to the exhaust end

E F PR / Siemens AG 2011
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Irsching IV Power Plant:
Test and Validation E F PR / Siemens AG 2011
Page 25 Vers. hf; 16.10.2011 frank.haffner@siemens.com Energy Sector
Process quality is the basis for products
creating maximum value for our customers

Product Development Process

Strategic Product Planning Design Sales Design Implementation Validation


Preparation

Product & Erection,


Commercia- Final Design Manufacturing Product
Product Development Conceptual Basic Install., Com-
lization & & Monitoring &
Strategy Planning, Tech. Design Design missioning &
Planning Procurement Assembly Validation
Acquisition Trial Operation

Parts testing
Casting blades and vanes
Materials, coatings
Manufacturing trials, etc.
Stress, strain verification

Component testing
Prototype
Combustion system rig
CC field
test
Cover plate rig test operation
Mock up

System testing
Compressor test &
Combustion system
test at test bed Berlin

E F PR / Siemens AG 2011
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Matrixed, multi-location team structure to integrate
Siemens experts worldwide

Development Team

Berlin, Germany Erlangen, Germany

Manufacturing Program Mgmt.


Engine Testing
Plant Design

Jupiter, FL, USA

Blades
Mhlheim, Germany Vanes
Secondary air
Compressor
Engine Integration Orlando, FL, USA

Turbine
Combustion System

E F PR / Siemens AG 2011
Page 27 Vers. hf; 16.10.2011 frank.haffner@siemens.com Energy Sector
Process quality is the basis for products
creating maximum value for our customers

Product Development Process

Strategic Product Planning Design Sales Design Implementation Validation


Preparation

Product & Erection,


Commercia- Final Design Manufacturing Product
Product Development Conceptual Basic Install., Com-
lization & & Monitoring &
Strategy Planning, Tech. Design Design missioning &
Planning Procurement Assembly Validation
Acquisition Trial Operation

Parts testing Prototype


Casting blades and vanes GT field
Materials, coatings testing
Manufacturing trials, etc.
Stress, strain verification

Component testing
Prototype
Combustion system rig
CC field
test
Cover plate rig test operation
Mock up

System testing
Compressor test &
Combustion system
test at test bed Berlin

E F PR / Siemens AG 2011
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Over 2800 additional sensors

Irsching Test DYNAC Vissio


Clients 1&2
EDAS-DR
Clients 1...5

Additional sensors Center


DYNAC
Station 1-7
BDAS Data

Over 2800 sensors measured: Mhlheim


shared VLAN
Mhlheim
Server

Temperatures
EDAS-DS
Station 1-5
Test Theme Online
Instrumentation Server
shared

Pressures
Router

Irshing Server
BDAS Data

Strains
Theme Online and
BDAS data Clients 1...n
with access to CAT services
Encryption
shared shared shared

Acceleration Irshing Server DYNAC Vissio EDAS-DR


Clients 1&2 Clients 1...3
Theme Online
SNX
Clearances
Telekom shared
Router
shared
shared

Vibrations
BDAS Data
Server
shared VLAN
Orlando Orlando
Irsching Site Office
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

Theme Online and


shared BDAS data Clients 1...n
VLAN with access to CAT services
Jupiter Jupiter

E F PR / Siemens AG 2011
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Time consuming thermal paint test ....

Scope: Major Hot Gas Parts

Basket (2)
Transition (2)
Vane 1 (12)
Vane 2 (6)
Vane 3 (2)
Blade 1 (6)
Blade 2 (6)
Blade 3 (6)
Vane Carrier Blade 4 (4)
Ring Segment 3 (2)

8 weeks for installation (outage)


1 hour operation, straight start
10 min. base load
6 weeks to remove tested parts

TB 1 TB 2
E F PR / Siemens AG 2011
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...successfully performed,
providing detailed temperature pictures.

397 MW

TB 4

Straight loading to base load required,


otherwise results not representative

Basket
Vane 1 ID
E F PR / Siemens AG 2011
Page 31 Vers. hf; 16.10.2011 frank.haffner@siemens.com Energy Sector
Irsching Test Experience & Objectives

1600

1500
Approximate
Demonstration of Total Hours
1400 engine integrity
1300 through endurance
1200 operation Approximate
Baseload Hours
1100
Operating Hours

1000

900
Verification of individual
800
component performance and
engine operation characteristics
700

600

500

400

300

200

100

0
20090228 20090330 20090430 20090530 20090630 20090730 20090830

E F PR / Siemens AG 2011
Page 32 Vers. hf; 16.10.2011 frank.haffner@siemens.com Energy Sector
Endurance Test Phase

Main Purpose

Collect further mid-long term operating experience, starts and hours, under semi-
commercial 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)

E F PR / Siemens AG 2011
Page 33 Vers. hf; 16.10.2011 frank.haffner@siemens.com Energy Sector
SGT5-8000H - significant operational experience

+ Successful cold & hot commissioning


+ Part load and base load operation Operating Data
+ Performance and emissions demonstrated
+ HCO and fuel preheat experience
+ Gained outage experience regarding burner exchange, Test days 122
bearing lift, cover lift TVC roll-in/out
Starts 174
+ Inspection experience on all components
+ High start up reliability Operation hours 1525 h
+ Start-up gradients up to 35 MW/min
OHs > 50% BL h
1404
+ Frequency Range 47,5 51,5 Hz demonstrated
+ Load rejection capability Full load OHs 1243 h
+ Ignition and Start-Up optimization
Power generated 470.000 MWh
+ Grid Code
+ Thermal Paint Test Gas consumption 122.220.000 Nm

+ Endurance Run (1143 OH)

E F PR / Siemens AG 2011
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Proven efficiency and output
proven economic advantages

Voice of the customer: E.ON Energie AG, Germany

Bernhard Fischer
Member of the Board
of Management
In actual operation, the SGT5-8000H
has more than met our high
expectations:
E.ON Energie AG,
Germany During roughly 1,200 hours of testing
in Irsching, Block 4, we were able to
experience the performance of the
worlds 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.

E F PR / Siemens AG 2011
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Combined Cycle Plant Design

E F PR / Siemens AG 2011
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SGT5/6-8000H Product Line
Performance and Configuration Overview

50 Hz 60 Hz

SGT-PAC 8000H 375 MW 274 MW


40 % 40 % SGT5/6-8000H

SCC-PAC 8000H 1S 570 MW 410 MW


> 60 % > 60 %

SCC-PAC 8000H 2x1 1.145 MW 824 MW


SCC5/6-8000H 1S
> 60 % > 60 %

SCC-PAC 8000H 3x1 -- 1.236 MW


-- > 60 %
at ISO conditions
SCC5/6-8000H 2x1
Siemens AG 2011
Page 37 8000H / Irsching 4 Sales INFO Energy Sector
SCC5-8000H 1S
Single Shaft Arrangement

SST5-5000 HRSG/Benson,
Condenser
(600C) 3P/RH 600C/170 bar

SSS Clutch

SGen5-3000W

Lube oil system SGT5-8000H

E F PR / Siemens AG 2011
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Single Shaft Arrangement

Gas Turbine Generator Excitation Clutch Steam Turbine

Journal Bearing Journal Bearings Journal Bearings


Journal Thrust-Bearing Journal Thrust-Bearing
Thermal Growth Thermal Growth

Thermal Compensation within Clutch

E F PR / Siemens AG 2011
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Multi Shaft Arrangement 8000H-
based on 4000F experience

E F PR / Siemens AG 2011
Page 40 Vers. hf; 16.10.2011 frank.haffner@siemens.com Energy Sector
E F PR / Siemens AG 2011
Page 41 Vers. hf; 16.10.2011 frank.haffner@siemens.com Energy Sector
Customer Benefit SCC5-8000H 1S
Start-up Curves

Start-up Cases Start-up Time Definition


Advanced FACY outage after <8h ~40 min 1) Plant Start-up Time begins with ignition of GT and
Warm Start outage after <64h ~100 min 1) is completed with GT at IGV base load position
(position >98%) as well as HP and IP/HRH bypass
Cold Start outage after <120h ~150 min 1) station closed.

Warm start curve

GT1 Speed (%) GT1 Load (%) ST Speed (%) ST Load (%) Plan Load (%)

1) expected values E F PR / Siemens AG 2011


Page 42 Vers. hf; 16.10.2011 frank.haffner@siemens.com Energy Sector
Customer Benefit SCC5-8000H 1S
Highest efficiency

Eff. = ~1.5%-Points
CC Gross Efficiency

SCC5-8000H 1S

SCC5-4000F 1S

50 60 70 80 90 100
CC Re. Power (%)

Highest performance in base and part load.

E F PR / Siemens AG 2011
Page 43 Vers. hf; 16.10.2011 frank.haffner@siemens.com Energy Sector
Irsching Units 1 - 5, as of July 2011

Unit 5 Unit 4 Unit 1 3


4000F 8000H convent. STs

E F PR / Siemens AG 2011
Page 44 Vers. hf; 16.10.2011 frank.haffner@siemens.com Energy Sector
SGT5-8000H / Irsching 4
Operational Status, as of Oct. 04, 2011

Phase I Phase II
GT Testing Combined Cycle
Starts 85 168*
Operating hrs 1525 2663
Dynamic hrs 1990 1639
Sub Total 4365 5982**

Grand Total appr. 10.300 EOH


* 98,2 % starting reliability, ** 99,8% operating reliability since PAC
Siemens AG 2011
Page 45 8000H / Irsching 4 Sales INFO Energy Sector
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
Page 46 8000H / Irsching 4 Sales INFO Energy Sector
SGT5-8000H / SCC5-8000H
The answer to market and customer requirements

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

E F PR / Siemens AG 2011
Page 47 Vers. hf; 16.10.2011 frank.haffner@siemens.com Energy Sector
SCC5-8000H 1S / Irsching 4
World Record Runs, 06.05.2011

Promised and Delivered !

*1 Irsching Site Conditions: Ambient temp. 9C, pressure 973mbar, rel. Humidity 81%, cooling water 10C Siemens AG 2011
Page 48 8000H / Irsching 4 Sales INFO Energy Sector
Siemens Combined Cycle Power Plant portfolio

50Hz GT and corresponding CCPP configuration

SGT5-8000H 375
50 Hz SGT5-4000F 292
GT
SGT5-2000E 168

SCC5-8000H 1S 570
SCC5-8000H 2x1 1.242
50 Hz SCC5-4000F 1S 434 Cold Climate
CCPP
SCC5-4000F 1S 429 Warm Climate

SCC5-4000F 2x1 832 Warm Climate

Siemens AG 2011
Page 49 8000H / Irsching 4 Sales INFO Energy Sector
Thank you

E F PR / Siemens AG 2011
Page 50 Vers. hf; 16.10.2011 frank.haffner@siemens.com Energy Sector