sgt5-8000h, product validation and operational experience
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Copyright © Siemens AG 2010. All rights reserved. 1
PowerGen Europe June 08-10, 2010
Copyright © Siemens AG 2010. All rights reserved.
SGT5-8000H, Product Validation and
Operational Experience at Irsching 4
Willibald J Fischer
Siemens AG
List of Content Abstract ...................................................................................................................................... 3
Introduction ................................................................................................................................ 4
Primary Targets of the 8000H Program ..................................................................................... 4
Major Milestones of the 8000H Program................................................................................... 5
SGT5-8000H Design Features ................................................................................................... 5
SGT5-8000H Validation ............................................................................................................ 6
Thermal Paint Test ..................................................................................................................... 8
Summary .................................................................................................................................... 9
References ................................................................................................................................ 10
Copyright © Siemens AG 2010. All rights reserved. 2
Abstract
The new SGT5-8000H gas turbine, which is the result of years of research and development
within Siemens Energy, is the first new frame developed after the merger of Siemens and
Westinghouse. It is based on well proven features of the existing product lines combined with
advanced technology.
Customer needs and benefits were the main drivers for the development of the new engine,
originally rated at 340 MW@ISO. The air-cooled concept offers added value through higher
operational flexibility required in deregulated market environment.
The SGT5-8000H turbine development team involved more than 250 engineers, working in
Erlangen, Berlin and Muelheim in Germany, as well as in Orlando and Jupiter in Florida,
USA. An additional 500 employees were involved in the manufacturing, assembly and test
preparation of the prototype engine.
Single gas turbine components were already pre-tested and verified with success. The
complete SGT5-8000H gas turbine was finally under a field validation in a real power plant
environment at Irsching 4 Power Station, Bavaria/Germany, in a hosting agreement with
E.ON.
This comprehensive and consequent approach will ensure, that subsequent “commercial”
engines will be brought to market in a risk controlled manner, fully validated based on
extensive operating history.
The paper will cover:
• Overview 8000H program
• Key features of new gas turbine and cc-plant
• Field validation approach
• Prototype project Irsching 4
• Status of validation phase and key test results
Copyright © Siemens AG 2010. All rights reserved. 3
Introduction
The worldwide need for energy is constantly rising while at the same time the demand for
reliable, affordable, efficient as well as environmentally-compatible power generation is
increasing. In today’s highly-competitive business environment, customers and power plant
operators expect an economical, state-of-the-art product. Their purchasing decisions place
more and more emphasis on life-cycle cost analyses that span the entire lifetime of a power
plant.
Siemens Energy developed its new generation H-class Siemens gas turbine (SGT™), the
SGT-8000H series, taking both environmental protection as well as economical focus into
consideration. Technical innovations in design and development, process engineering,
materials and manufacturing as well as assembly processes collectively support Siemens
Energy in continually transforming these new requirements into realities.
The H class gas turbine is the first new frame developed since the merger of Siemens and
Westinghouse. It combines the best features of the two established product lines with
advanced technology, the functional and mechanical design of the new engine were built on
the experience gathered with the predecessor 50Hz and 60Hz engines. Proven design features
were applied wherever possible, and "Design for Six Sigma" tools were used resolutely, to
deliver a competitive product which meets the requirements described in the foregoing.
Primary Targets of the 8000H Program
Customer requirements resulting especially from today’s liberalized energy markets and
current trends in today’s generation portfolio requirements for complementing the substantial
market penetration of renewable power, were the essential drivers for developing the new
SGT5-8000H: (Figure 1)
Increase of combined-cycle net efficiency to over 60%, Reduced emissions per kWh produced, Achievement of high efficiency and low emissions in part-load operation also, Fast start-up capability and operational flexibility, Reduced investment costs per kW, High reliability and availability, and ultimately Minimum life cycle costs.
The SGT5-8000H gas turbine development team involved more than 250 engineers, working
in Erlangen, Berlin and Muelheim in Germany, as well as in Orlando and Jupiter in Florida.
Copyright © Siemens AG 2010. All rights reserved. 4
An additional 500 employees were involved in the manufacturing, assembly and preparations
for testing the prototype engine.
This new turbine was developed in strict compliance with the company’s Product
Development Process. The design effort incorporated previous lessons learned, applied
proven design features wherever possible and systematically utilized Design for Six Sigma
tools to deliver a competitive product focused on life-cycle costs, performance, serviceability,
flexibility, reliability, and low emissions.
Major Milestones of the 8000H Program
Consequent program management is essential for successful introduction of a new gas
turbine. As already achieved during the design phase, all major milestones during the testing
period were achieved on time:
Program Launch – Concept Phase Oct. 2000 Gate 1: Product Strategy Mar. 2001 Gate 2: Start Basic Design (GT) Nov. 2001 Gate 3: Product Release (GT) Aug. 2004 1st engine shipment ex Works Berlin Apr. 2007 1st Fire at Irsching 4 Test Center Dec. 2007 1st Synchronization to power grid Mar. 2008 1st Base Load Apr. 2008 End of Test & Validation Phase Aug. 2009
SGT5-8000H Design Features
The engine concept was selected from a number of air-cooled engine design options and
several gas turbine cycle variants after completion of a comprehensive feasibility analysis
during the conceptual design phase. The air-cooled concept selected offers maximum added
value by virtue of its higher operational flexibility – an essential prerequisite in the
deregulated power generation market environment.
The most important gas turbine design features are: (Figure 2) • Single tie-bolt rotor comprising individual compressor and turbine disks with Hirth facial
serrations, • Hydraulic clearance optimization (HCO), • Axial 13 stage compressor with high mass flow, high component efficiency, controlled
diffusion airfoils (CDA) in the front stages and high performance airfoils (HPA) in the rear stages, variable guide vanes and cantilevered vanes,
Copyright © Siemens AG 2010. All rights reserved. 5
• High temperature, air-cooled, can annular combustion system, • Four-stage, exclusively air-cooled turbine section, • Advanced, on-board variable dilution air system, with no external cooling system, • Advanced, highly-efficient, high-pressure and high-temperature combined-cycle process
with a Benson boiler design based on the high mass flow and exhaust temperature of the new engine. (Figure 3)
A 60 Hz version is now in being elaborated based on the achievements of the 50 Hz project,
thereby minimizing operational risks for customers.
SGT5-8000H Validation
For minimization of customer risk during the introduction of a new product, a comprehensive
test and validation program was set up. This already included tests on prototype parts during
the design phase, followed by sub-system validation such as atmospheric and high pressure
combustion testing, as well as full-scale, 60 Hz compressor validation. The individual
components, sub-systems and then engine tests were performed in the Siemens Berlin test
center and at several other suitable test facilities. (Figure 4)
The crucial phase of validation is engine operation under real power plant conditions.
Preparation for this phase was already commenced in 2005 with the installation of about 3000
sensors in and on the engine during manufacture of the prototype. In addition to the standard
I&C system, these sensors measure temperatures, pressures, strains, flows, acceleration, and
vibrations encountered during part load and base load operation and enable engineering to
compare the design models with the real engine response. Two telemetry systems located at
the turbine bearing as well as the compressor end of the intermediate shaft delivered some 600
additional signals from the rotor.
The partner found for this extensive validation project is E.ON Kraftwerke, a major German
electricity provider. A very unique contract was entered to give Siemens maximum flexibility
in testing the new gas turbine and add the world’s first combined-cycle power plant with 60%
efficiency to the E.ON power plant fleet.
The contract defines two phases. During the first phase, Siemens built a gas turbine power
plant in a simple-cycle configuration and operated this plant for 18 months for testing
purposes under the terms of a hosting agreement. The existing Irsching power plant site was
selected for this common project. Site preparation started in 2006. The second phase of the
contract, which started after completion of the 18-month test phase and demonstration of the
Copyright © Siemens AG 2010. All rights reserved. 6
contractually-defined performance of the gas turbine, covers the extension of the simple cycle
configuration to a single-shaft, combined-cycle power plant that will be commissioned and
handed over to the customer as under the terms of a turnkey EPC arrangement.
To operate the gas turbine during the 18-month test phase, additional contracts with a gas
provider and for the sale of electricity have been implemented. The gas contract does not
stipulate any minimum gas consumption. The electricity sales contract covers any power
which is produced by operation of the gas turbine. Both contractual arrangements allow
maximum testing flexibility for validation of the gas turbine.
The engine was shipped from the Siemens gas turbine manufacturing plant in Berlin plant at
the end of April 2007 and was placed on the foundation at the Irsching 4 site at the end of
May 2007. During engine installation, a considerable scope of additional instrumentation such
as externally-mounted blade vibration sensors, pyrometers, tip clearance and flow field probes
as well as two infrared turbine blade monitoring cameras was installed.
Concurrent with erection of the power plant, test facilities including the extensive data
acquisition system (DAS) were added. The DAS set-up was not limited to the Irsching site. A
dedicated encrypted data network between the Irsching Test Center and the engineering
headquarters in Muelheim, Germany and Orlando, Florida was established. This network
enabled 100 additional engineers to have a live view of engine operation without the need for
on-site presence and contributed to both testing operations as well as engine safety. (Figure 5)
Cold commissioning of the gas turbine was successfully completed in December 2007. The 4-
phase structured testing operation was commenced with the successful first fire on December
20, 2007 (Figure 6). The first test phase was mainly driven by auxiliary and start-up
commissioning steps. The start-up and protection settings were optimized. Also mandatory
full speed no load (FSNL) tests such as speed sweeps for compressor and turbine validation
and generator protection testing were also conducted. Test phase 1 ended with the first
synchronization with the grid on March 7, 2008.
Test phase 2 included the first loading to full speed full load (FSFL) and all related tests for
optimizing the loading schedule for the four stages of variable guide vanes as well as the five
fuel gas stages of the combustion system. Test phase 2 culminated in achieving base load for
the first time on April 24, 2008.
The primary focus of test phase 3 was mapping of aerodynamic and thermodynamic
performance at part load and base load as well as final combustion tuning to meet emissions
requirements. Test phase 3 also included tests with preheated fuel at various loading rates and
Copyright © Siemens AG 2010. All rights reserved. 7
also load rejection tests. Pyrometers were utilized to gain a more comprehensive picture of
surface temperatures of the rotating turbine parts. Flow probes were installed in the diffuser
and in the turbine flow path to determine the flow fields.
Thermal Paint Test
Thermal paints, also known as temperature indicating paints, are a simple and effective means
to obtain a permanent visual record of the temperature variations over the surface of
components. Thermal paints do not modify the thermal behavior of a component during
testing and can be applied to surfaces with small-diameter cooling holes without affecting the
cooling effectiveness. Thermal paint tests entail a significant investment in terms of testing
time and financial expenditure.
A comprehensive thermal paint test was conducted at Irsching 4. For this test, two extensive
outages involving cover lifts were required. During the first 8-week outage, several parts with
thermal paint were installed in the combustion and turbine sections.
On January 30, 2009, the engine was restarted and loaded directly to base load for 10 minutes
of operation. Precise timing of the operating sequence was mandatory to produce
representative results. Overall, the test run itself only took one hour. Subsequently, the unit
was shut down to remove the painted parts during the second outage which lasted another six
weeks. In the following months, the color changes were evaluated and very valuable
temperature profiles over the entire surface of the hot gas path parts determined.
At the end of test phase 3 in April 2009, the engine had accumulated operating 300 hours. The
mortality rate of the prototype sensors was comparatively low and thus terabytes of very
valuable data were recorded and can be used for further evaluations in the future. Having
completed test phases 1-3, all specific operational tests were successfully concluded. During
these 15 months of testing, frequent inspections were conducted and valuable service and
outage experience was also gained. For example, the overall effort of the thermal paint test
described above is comparable to the effort required for an extended hot gas path inspection.
Test phase 4 is the so-called Endurance Test and has the main purposes: (Figure 7)
• Collection of further mid-to-long-term operating experience, starts and hours under semi-
commercial conditions,
• Confirmation of “readiness for commercial service”, based on the load regime required by
grid operator,
• Operation by staff without special qualification (other than standard GT O&M
experience), and
Copyright © Siemens AG 2010. All rights reserved. 8
• Recording of test sensor data will be continued, however the prime focus is no longer on
testing.
The operating parameters are set and the engine was operated 24 hours for extended
continuous periods as well as on a daily start-and-stop basis in line with load dispatch
requirements.
When this test phase is completed in the summer of 2009, the engine will have logged
operating experience equivalent to 200 starts and 3000 operating hours. This clearly
completes a success story of gas turbine validation.
Summary
Key parameters such as the compressor pressure ratio and aerodynamic efficiency,
temperatures of hot gas path parts, combustion dynamics behavior, as well as engine output,
vibration and emissions have been validated and demonstrated (Figure 8). The key
performance parameters of the SGT5-8000H met or even exceeded expectations and the
engine has convincingly proven its capability as a 400 MW class gas turbine under test
conditions.
After completion of test phase 4, during which the gas turbine was in simple-cycle operation,
the Irsching 4 plant is now being converted into a single-shaft combined-cycle power plant.
Takeover by E.ON Kraftwerke and subsequent commercial operation of the plant are
scheduled for 2011.
Based on careful evaluation of test data and comparison with design predictions, Siemens
Energy is now able to offer uprated performance of the 8000H system as follows:
SGT5-8000H SCC5-8000H 1S
Introductory Rating
Output 340 MW 530 MW
Efficiency > 39 % > 60 %
New Rating Output 375 MW 570 MW
Efficiency 40 % > 60 %
(Figure 9)
Copyright © Siemens AG 2010. All rights reserved. 9
Based on the positive experience resulting from the 1½-year test phase at Irsching 4, Siemens
Energy is now in a position to offer the 8000H system to the power generation market for
commercial applications.
References
[1] “Building the world’s largest gas turbine”, Modern Power Systems, Germany
Supplement 2006.
[2] „Neue Gasturbinen für mehr Kundennutzen“, VGB-Kongress, Kraftwerke 2006, Dr.
Wolf-Dietrich Krüger, Siemens AG Power Generation.
[3] Kleinfeld, K., Annual Shareholders' Meeting of Siemens AG on January 25, 2007.
Report by President and CEO of Siemens AG Dr. Klaus Kleinfeld.
[4] Ratliff, P.,Garbett, P., Fischer, W., „SGT5-8000H Größerer Kundennutzen durch die
neue Gasturbine von Siemens“, VGB PowerTech, September 2007.
[5] U. Gruschka, B. Janus, J. Meisl, M. Huth, S. Wasif, ULN system for the new SGT5-
8000H Gas Turbine.
Copyright © Siemens AG 2010. All rights reserved. 10
Fig. 1 IDGTE 2009, Milton Keynes Energy SectorCopyright © Siemens AG 2008. All rights reserved.
Increase of combined cycle net efficiency to over 60%
Reduced emissions per produced kWh
High efficiency and low emissions also in part-load operation
Fast start-up capability and operational flexibility
Reduced investment costs per kW
High reliability and availability
Resulting in Lowest life cycle costs
SGT5-8000H / SCC5-8000HThe answer to market and customer requirements
Fig. 2 IDGTE 2009, Milton Keynes Energy SectorCopyright © Siemens AG 2008. All rights reserved.
Harmonization of ‘V’ and ‘W’ frames uses best featuresfrom both and introduces new technologies on low risk
≥ 60% Combined Cycle efficiency
Integrated combined cycle processfor economy and low emissions
High cycling capability due to advanced blade cooling system
Evolutionary 3D-compressor bladingProven rotor design, Hirth serration and
central tie rod
Four stage turbine with advanced materials and thermal barrier coatingAdvanced ULN*
combustion system
*Ultra Low Nox
SGT5-8000H – World’s largest gas turbine
Copyright © Siemens AG 2010. All rights reserved. 11
Fig. 3 IDGTE 2009, Milton Keynes Energy SectorCopyright © Siemens AG 2008. All rights reserved.
SGT5-8000H / SCC5-8000H, Key Data
Fuel Nat. gas, #2
GT output 375 MW
CC outputnet 570 MW
CC efficiencynet 60%
Pressure ratio 19.2 : 1
Exhaust mass flow 820 kg/s
Exhaust temperature 625 °C
Turn down 50%
HRSG/WS-Cycle 600°C/170 barBenson
SGT5-8000H
SCC5-8000H
at ISO conditions
Fig. 4 IDGTE 2009, Milton Keynes Energy SectorCopyright © Siemens AG 2008. All rights reserved.
Sales PreparationStrategic Product Planning Design Design Implementation Validation
Product StrategyTechn. Acquisition,
Product,Technology & Developm. Planning
Conceptual Design
Basic Design
Commerciali-zation Planning
Manufacturing & Assembly
Erection, Installation,Commissioning and
Trial OperationProduct
MonitoringPerformance &
Reliability Validation
Final Design & Procurement
Parts tests• Casting blades & vanes• Materials, coatings• Manufacturing trials etc.• Stress / Strain verification
Component tests• Combustion system rig test • Cover plate rig test • Mock up
Systems tests• Compressor test &• Combustion system test
at test bed Berlin
Prototype GT field validation
Prototype CC field operation
Siemens invested over 500’ EUR to develop an advanced but robust product andconfirmed its integrity to ensure lowest customer risk.
Validation of advanced technologies in test rigs before prototype engine testing
8000H Program includes a Comprehensive Validation and Testing Concept
Copyright © Siemens AG 2010. All rights reserved. 12
Fig. 5 IDGTE 2009, Milton Keynes Energy SectorCopyright © Siemens AG 2008. All rights reserved.
SGT5-8000H Field ValidationSensor, Data Acquisition & Data Transfer Concept
2838 Sensors
1688 Temperatures616 Pressures357 Strain Gages59 Accelerometer48 Clearances56 Blade Vibration14 Flows & Forces
597 rotating2241 stationary
458 dynamic2380 quasi-static
Fig. 6 IDGTE 2009, Milton Keynes Energy SectorCopyright © Siemens AG 2008. All rights reserved.
Test & Validation Phase, Overview
Build 1 Testing (January – July 2008)
2nd Build Outage (August – October 2008)
Build 2 Testing, Phase 1 (November – December 2008)
Thermal Paint Outage & Test (December 08 – March 2009)
Build 2 Testing, Phase 2 (March – April 2009)
Final Build Outage (May 2009)
Endurance Test Phase (May – August 2009)
Copyright © Siemens AG 2010. All rights reserved. 13
Fig. 7 IDGTE 2009, Milton Keynes Energy SectorCopyright © Siemens AG 2008. All rights reserved.
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)
In total, operating experience corresponding to the equivalent of 200 Starts and 3.000 Hours have been accumulated during the Validation & Test Phase.
Fig. 8 IDGTE 2009, Milton Keynes Energy SectorCopyright © Siemens AG 2008. All rights reserved.
SGT5-8000H Successful validation as basis for market introduction
1st fire achieved onschedule
Stable and reliableignition from 1st start
Base load within 9days of operation from 1st synchronisation
High starting reliabilityalready achieved very early
Overall integrity, Performance,Emissions confirmed
Endurance Testing conducteduntil End of August 2009
Validation program completed on track: overall stability, vibrations, performance, emissions and operational flexibility fully confirmed.
Copyright © Siemens AG 2010. All rights reserved. 14
Copyright © Siemens AG 2010. All rights reserved. 15
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