Gas Turbine Technology: Challenges, Achievements, Outlook

Gas Turbine Technology: Challenges, Achievements, Outlook Session GT Technology Trends Wolfgang Menapace, Siemens Energy Sector 4. IGT Conference, E...
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Gas Turbine Technology: Challenges, Achievements, Outlook Session GT Technology Trends

Wolfgang Menapace, Siemens Energy Sector

4. IGT Conference, ETN Brussels, October 15 – 16, 2008

© Siemens Power Generation, Inc. 2007. All rights reserved

Gas Turbine Technology: Challenges, Achievements, Outlook

Question 1: Is there a future market for Gas Turbines ? Core requirements Competing plant concepts

Page 1

4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008

© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT

Strong steam and combined cycle segments, growth in nuclear power market over next decade World power market [GW/a] 202 13

178 23

147

144 115 ST nuclear

3

68 (China 62)

21

(China 48)

of it ST 126

82 of it ST 101

77 STPP

of it ST 133

96

8

(China 49)

of it ST 85

61 (China 40)

of it ST 101

(China 30)

75 CCPP GTPP

45 38 7 Avg 02-04

STPP: CCPP: GTPP: Page 2

of it GT 30

of it GT 69

of it GT 43

62 of it GT 52

52 of it GT 46

14

19

12

13

Avg 05-07

Avg 08-10

Avg 11-13

Avg 14-18

Steam Turbine Power Plant Combined Cycle Power Plant Gas Turbine Power Plant

ST: GT:

Steam Turbine Gas Turbine

4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008

Deviations due to figure rounding

© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT

Customers operate Gas Turbines in different scenarios resulting in different requirements Electricity price Fuel cost

Peaker CT

• Start-up Reliability • Power Output

10 • Reliability • Efficiency • Power Output

5

• Efficiency • Reliability, availability • Maintenance costs

Intermediate CC

2 Base load CC

1 peaking

intermediate

Hours per year

base load 8760

Page 3

4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008

© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud

Copyright (C) Siemens AG - Siemens Management Consulting 2004 All Rights Reserved - Confidential

L:3_01_Power_Gen_2008_IGT_GTT

Business Drivers and Customer Requirements for today's and future Gas Turbine engines Business Drivers

Customer Requirements § Power ↑

Engine Performance

+

§ Efficiency ↑ § Emissions ↓ § First Time Cost ↓ § Operational Flexibility

Reliability / Availability / Maintainability (RAM)

§ Cycling Capability ↑ § Fuel Flexibility ↑ § Upgradeability ↑ § Regulatory Compliance ↑

Market / Competitiveness

§ Product Robustness ↑ § Maintenance Cost ↓

Page 4

4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008

© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT

Example for customer evaluation

1% efficiency increase results in Fuel Cost reduction of 1.500.000 €/a* CO2-reduction of

~ 25.000 t/a

per Combined Cycle Power Plant with 400 MW @ 8000 h/a

*based on: 6.5 €/GJ fuel cost

Main driver of economic assessment: Efficiency Page 5

4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008

© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT

Competing plant concepts in today's fossil market Comparison of fossil power generation technologies 2010 Gas-fired Combined Cycle Power Plant (CCPP)

Coal-fired Steam Power Plant (STPP)

w/o CO2 – Capture

w/o CO2 – Capture

Integrated Coal Gasification CCPP w/o CO2 – Capture

60%

125% 100%

Plant net efficiency 47%

> 47%

lower risk § tested in test rigs, test bed engine or rainbow test in the field § retrofit-ability for field validation and service upgrades

Evolutionary Design leads to Performance and Flexibility Improvements without risking Reliability and Availability

Page 8

4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008

© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT

Evolution: Major Upgrades of our SGT5-4000F -

Latest Upgrade

1st Compressor Upgrade 2. Upgrade 292 MW / 39.8% 1. Upgrade

Cooling Air Reduction 287 MW / 39.5%

Market Introduction 266 MW / 38.6%

240 MW / 37.0% 1996

2000

• 2nd Compressor Upgrade • Combustor Cooling Air Saving • Hydraulic Clearance Optimization • Fuel Gas Preheating 2004

2008

Successful history of continuous improvements

Page 9

4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008

© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT

Example for Advanced Technology: SGT5-4000F Design Features • Compressor, 15 stage advanced 3-D airfoil design in all stages and with side-wall correction. One variable guide vane row. • Combustion System - annular, low pattern factor - Dry low NOx and dual fuel • 4 stage Turbine. - SX row 1 and SX/DS 2 blades - Film-cooling, TBCs • Rotor with Hirth serration and single tie bolt. Quick thermal response because of rotor internal flow passages. Steel based materials only • Excellent thermal balance due to: - Quick and stiff rotor - Conical turbine flow path • Due to thermal balance: - Quick start up - Hot restart capability

Page 10

4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008

© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT

Operating Fleet Experience Summary

Our advanced Gas Turbine Family SGT5-4000F, SGT6-4000F, SGT5-3000E, SGT-1000F (Vx4.xA) has clocked up more than 5,200,000 EOH* (Status March 2008)

> 190 engines in operation. > 65 engines on order

The Reliability of the SGT5-4000F Gas Turbine is at the same high level (> 99%) as our mature fleet

* = Equivalent Operating Hours Page 11

4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008

© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT

Gas Turbine Technology: Challenges, Achievements, Outlook

Question 3: What are the next steps and recent experiences of our GT development ?

Page 12

4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008

© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT

60% CCPP efficiency is targeted with advanced gas turbine and steam cycle design CCPP efficiency development

Net Plant Efficiency [%]

Steam cycle development

% 60

from single pressure to triple pressure reheat steam cycle

58

110 bar 540 °C

75 bar 510 °C

52 50 48

50 bar 460 °C

46

960 °C

60 bar 485 °C

1250 °C

100 bar 1190 °C 520 °C

56 54

>130 bar 130 bar 565 °C 565 °C >1250 °C

80 bar 520 °C

1160 °C

1120 °C

1050 °C

1000 °C

Continuous improvement in material & coating, thermodynamic design, e.g.: - Thermal barrier coating - Fuel preheating - 3D blading

Gas turbine development

Fuel: natural gas ISO conditions: 15 °C, 1013 mbar, 60 % humidity

Page 13

4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008

© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT

60% CCPP efficiency will be demonstrated at Irsching 4 Power Plant Combined cycle plant efficiency development

SGT5-2000E (V94.2)

SGT5-4000F (V94.3A)

SGT5-4000F (V94.3A)

CCPP Killingholme, 2 x 450 MW

CCPP Didcot “B” 710 MW + 702 MW

CCPP Mainz-Wiesb. > 400 MW

CCPP Irsching 4, > 530 MW

1996

2001

2008/11

1992

Page 14

4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008

SGT5-8000H (new platform)

© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT

Siemens advanced air-cooled gas turbines are designed for highest efficiency and reliability Siemens SGT5-8000H gas turbine design features High cycling capability due to advanced blade cooling system

Four stage turbine with advanced materials and thermal barrier coating

Advanced can annular combustion system Evolutionary 3Dcompressor blading

Proven rotor design, Hirth serration and central tie rod

Page 15

4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008

© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT

SGT5-8000H and SCC5-8000H Key Data

Gas turbine

SGT5-8000H

Steam turbine

SST5-5000

Generator

SGen5-3000W

Fuel

nat. gas, #2

GT / CC output

340 / 530 MW

GT / CC efficiency

> 39% / > 60 %

Pressure ratio

19.2 : 1

Exhaust mass flow

820 kg/s

Exhaust temperature

625 °C

Turn down

50%

HRSG / WS-Cycle

Benson 3Pr-RH

SGT5-8000H

SCC5-8000H

600°C / 170 bar

Page 16

4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008

© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT

SGT5-8000H Prototype Test Schedule

2008

2007

2009 Gate 4

First Fire

Test-Phase: Test Program

Page 17

1

Start Up Tests

2

Part Load Tests

3

Full Load Tests

4

Endurance Tests

4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008

© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT

The SGT5-8000H meets Customer Needs for reduced Life Cycle Cost & Flexibility

MW Demand

Customer Needs

Rapid growth

Innovative Solution

Validation and Implementation

Peak Load Intermediate Load

Base Load

§ § § §

High thermal efficiency High availability Operational flexibility Reduced life cycle costs

Page 18

§ § § §

Air cooled 60% combined cycle efficiency Design for serviceability Manufacturing innovations

4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008

§ Performance validated before series release § Siemens controlled environment § 3,000 measurement points § Knowledge brought to design tools

© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT

Gas Turbine Technology: Challenges, Achievements, Outlook

Question 4: What shows the Outlook ? - Coal-to-Gas Technology: Perspectives for IGCC - Key technologies to advance

Page 19

4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008

© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT

IGCC plants may become in 2020 a third alternative with ~50% efficiency w/o and >43% with CO2 capture IGCC process principle

Siemens core competencies

Page 20

4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008

© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT

Siemens was involved in all European coal-based IGCC demonstration plants …… IGCC plant efficiency development

253 MW (net), start -

V94.2

V94.3

Buggenum (Netherlands), 253 MW (net)

1994

Page 21

-

4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008

Puertollano (Spain), 298 MW (net)

1997 © Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT

Development of Blades and VanesThe Key of highly sophisticated Gas Turbines 1975

2001 Aerodynamics Cooling technology Materials and casting Coatings (oxidation, corrosion) Thermal barrier coating

APS

Substrate

Uncooled Blade ~ 900° Hot gas temperature

EB PVD

Film cooled Blade >1400° Hot gas temperature

columnar structure

Substrate

Page 22

200 µm

50 µm

4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008

© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT

Advanced Material Systems are a key technology to advanced Gas Turbine Technology Closed-loop Cooling

allowable Hot Gas Temperature

Temperature

Temperature /°C

CMC

Film Cooling

Allowable Material temperature

TBC

IN738

2nd Gen. SX

IN939 IN792 DS

1st Gen. SX

U700 1965

1975

1985

1995

2005

2015

Year

Today TBCs are the Material Technology with the highest pay-off Page 23

4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008

© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT

Summary Gas Turbines will keep a prime role in the power market Our Evolutionary Design Approach blends Performance Improvements and Reliability Advanced Gas Turbines need intensive R&D and testing / validation Coal-to Gas/ IGCC Technology will be a growing alternative but requires adapted gas turbine technology Advanced Materials are key to develop advanced Gas Turbines

Page 24

4. IGT Conference, ETN, Brussel Oct. 15 -16, 2008

© Siemens Power Generation, Inc. 2007. All rights reserved. Siemens Energy Sector PR MK /Menapace/Dr.Taud L:3_01_Power_Gen_2008_IGT_GTT

Thank you

© Siemens Power Generation, Inc. 2007. All rights reserved