vgb conference gas turbines and operation of gas - siemens

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Protection notice / Copyright notice © Siemens AG 2009. All rights reserved. VGB Conference Gas 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 AB Finspong, Sweden

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V16_VGB_2013_SGT-600_NavrotskyProtection notice / Copyright notice© Siemens AG 2009. All rights reserved.
VGB Conference Gas Turbines and
Operation of Gas Turbines 2013
11-12 of June 2013, Friedrichshafen, Germany
Gas Turbine Performance and Maintenance Continuous Improvement
Dr. V. Navrotsky,
VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden Page 2
1. Introduction
3. Emission reduction
5. Maintenance Down Time reduction
6. Maintenance cost reduction
9. Summary
Outline
Page 3 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
ia l T
SGT6-8000H 266
SGT-750 36
(MWe)
Siemens offer a wide power range of Gas Turbines for Industrial and O&G markets
Page 4 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
Two shaft Gas Turbine 10 stage compressor (PR=14)
Two stage compressor turbine
Two stage power turbine
Welded compressor rotor,
Abradable coating on all stator rings
2:nd generation Dry Low Emission Comb.
Integrated by-pass system The design for PG is the same as for a MD
VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden Page 5
Outline
3. Emission reduction
5. Maintenance Down Time reduction
6. Maintenance cost reduction
9. Summary
Page 6 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
DLE introduced 1991 Total of units sold today is 300+
66% in Mechanical Drive (MD) application 34% in Power Generation (PG)
Total fleet operating hours > 7+ million hours 5+ million of those on DLE
Fleet leaders: > 160 000 hours > 3 600 starts
Fleet details
The SGT-600 evolution
SGT- 600 Key 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 Temperature 543 °C
2rd generations DLE emission:
Technical details
Prototype testing 300+ units by SiemensTransfer4 units by
Sulzer
Siemens
Outline
3. Emission reduction
5. Maintenance Down Time reduction
6. Maintenance cost reduction
9. Summary
Page 8 VGB 2013, Friedrichshafen, Germany 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)
VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden Page 9
Outline
3. Emission reduction
5. Maintenance Down Time reduction
6. Maintenance cost reduction
9. Summary
Page 10 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
Life Cycle Extension Program Life Cycle extension – LTA / LTE
Level “E“ + LTA
LTE
10‘ 20‘ 30‘ 40‘ 50‘ 60‘ 70‘ 80‘ 90‘ 100‘ 110‘ 120‘ 130‘ 140‘ 150‘ 160‘
EOH x 1000
Life Time Extension
agreed with customer
customer
Status determination of major components:
Non-destructive
Tailored scope of repair & replacement parts for LTE
Page 11 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
Compressor turbine vanes # 1 & 2
Compressor turbine blades # 1
Life Cycle Extension Life Cycle extension = LTA + LTE
Tailored scope of repair & replacement parts for LTE
Page 12 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
Blade grooves
VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden Page 13
Outline
3. Emission reduction
5. Maintenance Down Time reduction
6. Maintenance cost reduction
9. Summary
Page 14 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
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”
Operation Maintenance
Major Overhaul
n s
The Extension of Maintenance Intervals can improve the availability by up to ~ 1 %
.
Compressor blade
extraction tool
Outline
3. Emission reduction
5. Maintenance Down Time reduction
6. Maintenance cost reduction
9. Summary
Page 17 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
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
Compressor abradable ring recoating
Turbine blade #1 repair
Rotor seal edge 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-600 Repairs according to maintenance plan & on condition
Page 18 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
Turb blade #1
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 19 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
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
Page 20 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
DLE Combustor repair
Typical repair actions:
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
B. Replacement of inner and outer
liner
burners
options are required
Page 21 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
Turbine GV #1
shape
Final insp. incl flow properties
Page 22 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
Turbine GV #2
• Final insp. Incl. flow properties
Page 23 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
Honeycomb repair
2. Clean part by light grit blast
3. Remove old HC
4. Inspect and assessment
7. Final inspection
Page 24 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
Compressor abradable ring repair
2. Clean part by light grit blast
3. Remove old coating by machining
4. Inspect
8. Final inspection
Page 25 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
Repair technology development
To offer different repairs at reasonable prices Siemens is continuously developing and updating different repair technologies and methods.
Laser Cladding Technology
Outline
3. Emission reduction
5. Maintenance Down Time reduction
6. Maintenance cost reduction
9. Summary
Page 27 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden 27
Expert
Network
Team
Outline
3. Emission reduction
5. Maintenance Down Time reduction
6. Maintenance cost reduction
9. Summary
.
1200
TargetBaselineDescription
600 Increased cycle based TBO, without reduced T7-limit at hot ambient conditions.
30’ EOH Increased 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 %MD
18.3 MWMD
Focus on further Emission & Downtime reduction, Flexible operation & life extension (including cyclic life)
36 60 52 60 27 60 52 60
VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden Page 30
Outline
3. Emission reduction
5. Maintenance Down Time reduction
6. Maintenance cost reduction
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 EOH extension 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
Page 32 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden 32
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 SEC’s 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.
Page 33 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden 33
Thank you for your attention!
Copyright © Siemens AG 2008.
Page 34 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
Operation with varying Wobbe-index (WI)
78
‘’Normal’’ Pipeline NG High Calorific Value (HCV)
Wobbe Index (MJ/Nm³)
Low Calorific Value (LCV)
25
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
Page 35 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
Repair as part of maintenance concept
120’ EOH New & Clean 0 EOH
Level B 20’ EOH
Level C 40’ EOH
Level D 60’ EOH
Level E 80’ EOH
Level B 100’ EOH
CT Blade 1, Set #2
CT Blade 1, Set #3
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
NEWCT Vane 1, Set #2
RECONDITIONED
RECONDITIONED
RECONDITIONED
NEW
NEW
RECONDITIONED
RECONDITIOND
NEWPT Blade 3, Set #3
Page 36 VGB 2013, Friedrichshafen, Germany Dr. V. Navrotsky Siemens Industrial Turbomachinery AB, Finspong, Sweden
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
PAS, IrelandN/APtAlYesYesYesTurbine Vane 2
Turbocoating, ItalyAPSPtAlYesN/AYesTurbine Blade 1
PAS, IrelandN/APtAlYesYesYesTurbine Vane 1
Only applicable for conv.
Recotech, SWN/AMetco 307YesN/ANoAbradable rings