Power Gen Europe, Vienna / June 2013 SGT5-4000F Gas Turbine and Combined Cycle Power Plant Evolution reflecting the changing Market Requirements How Combustion Technology contributes to Performance and Flexibility Improvement Dr. Eberhard Deuker, Siemens Energy Unrestricted © Siemens AG 2013 All rights reserved.
siemens.com/answers
Former CCPP market drivers
Main Mainmarket marketdemand demandin inthe thepast: past: Highest Highestload load&&efficiency efficiency @ @baseload baseloadoperation operation
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Future CCPP market drivers: One answer is not enough… Highest efficiency through the whole load range including transient operation modes
Efficiency
H-gas, L-gas, LNG,... Large Wobbe Range
Power on Demand
Grid Support
Stable operation in case of grid incidents
Rapid availability - Fast start up - Fast shut down - Peak load capability
Fuel Composition Fuel Flexibility Unrestricted © Siemens AG 2013 All rights reserved. Page 3
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Table of Content • Introduction
SGT5-4000F Gas Turbine and • Major Development Steps Performance Improvement Emissions Improvement
Combined Cycle Power Plant Evolution reflecting the changing Market Requirements
• Operational Flexibility Fast Cycling Grid Support Wobbe Range Extension aSMC
Special focus: How combustion technology contributes to performance and flexibility improvement.
• Summary
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SGT5-4000F Evolution
Major Development Steps of the SGT5-4000F Performance Improvement Emissions Improvement
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SGT5-4000F Evolutionary Development Steps Adjusted pressure ratio 2nd compressor upgrade Combustor cooling air saving Hydraulic clearance optimization Fuel gas preheating
1st compressor upgrade
Cooling air reduction
Upcoming improvement steps
3. Upgrade 2. Upgrade 292 MW 39.8%
1. Upgrade
Improvement step
287 MW 39.5%
Market Introduction 266 MW 38.6% 240 MW 37.0% 1996
2000
2004
2008
2010
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SGT5-4000F Evolutionary Development Steps Adjusted pressure ratio 2nd compressor upgrade Combustor cooling air saving Hydraulic clearance optimization Fuel gas preheating
Cooling air reduction
Upcoming improvement steps
3. Upgrade
••Evolutionary Design 2. Upgrade Evolutionary DesignPrinciple Principle
1st compressor upgrade
Market Introduction
• Fully Retrofitable Retrofitable
Fully 1. •Upgrade
292 MW 39.8%
Improvement step
••Upgrade 287 MW Available Upgrade Packages Packages Available 39.5%
266 MW 38.6% 240 MW 37.0% 1996
2000
2004
2008
2010
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SGT5-4000F Evolution
Major Development Steps of the SGT5-4000F Performance Improvement Emissions Improvement
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SGT5-4000F Evolution
NOx emissions
SGT5-4000F baseline Evolution step 1
Premixed pilot
Evolution step 2
Main swirler optimization Evolution step 3
< 20 ppm 15 ppm Flame temperature
Consequent Reduction of NOx Emissions in several Development Steps Unrestricted © Siemens AG 2013 All rights reserved. Page 9
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2010 Upgrade NOx Emissions at Partload Conditions Significant decrease of NOx in the part load range of approx. 40 to 100% Guarantee level
Daily Average of NOx Emissions can drop considerably below the Guarantee Level if an Engine is running frequently in Partload Operation Unrestricted © Siemens AG 2013 All rights reserved. Page 10
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SGT5-4000F Evolution Turbine Exhaust Temperature
CO Emissions
Main driver for CO improvement: less compressor air mass flow (at constant load)
*
GT-Load [%]
CO Emissions
higher turbine exhaust temperature, higher flame temperature *
less CO
* for upcoming upgrades
GT-Load [%]
Emission compliant load range has been increased step by step Unrestricted © Siemens AG 2013 All rights reserved. Page 11
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SGT5-4000F Evolution
Operational Flexibility Fast Cycling Grid support Wobbe Range Extension aSMC Unrestricted © Siemens AG 2013 All rights reserved. Page 12
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Operational Flexibility: Advanced start-up with FACYTM and grid support Advanced start-up with FACYTM
Grid support
• Conserve hot/warm starting conditions during plant standstill • Automation concept with turbine stress controller • Start on the fly: Improved start-up sequence
SGT5-4000F is capable to fulfill the UK grid code: • Island operation • Primary frequency response
Plant Load
Improved Start-up Curve
• Grid sustaining Improvement
< 30 min.
Current Start-up Curve
Overfiring Comp. Turn- Up
Shortest start-up time Plant life design limit increased Highest starting reliability
1)
Fast IGV
Fast Wetcompression
Time 1) Expected Plant Start-up Time
With FACY™ Start-Up Concept Full Load is reached in 30 Minutes SGT5-4000F is capable to fulfill the UK grid code Unrestricted © Siemens AG 2013 All rights reserved. Page 13
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SGT5-4000F Evolution
Operational Flexibility Fast Cycling Grid support Wobbe Range Extension aSMC Unrestricted © Siemens AG 2013 All rights reserved. Page 14
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Operational Flexibility: Wobbe Range Extension Possible Wobbe Range for a selected NOx and TiT Target TC1 = 15ºC | rel. hum. = 60%
NOx NOxtarget target==20 20ppm ppm
Wobbe range: 40 to 51 MJ/m3
gas temperature reduction
TiT
reference level
200°°C
high combustion dynamics for cold gas
38
40
42
130°°C
NOx limit for hot gas
80°°C 40°°C
44
46
48
50
52
Wobbe [MJ/Nm³]
Wobbe range can be extended by adapting the fuel gas temperature Unrestricted © Siemens AG 2013 All rights reserved. Page 15
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SGT5-4000F Evolution
Operational Flexibility Fast Cycling Grid support Wobbe Range Extension aSMC Unrestricted © Siemens AG 2013 All rights reserved. Page 16
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Operational Flexibility: aSMC (advanced Stability Margin Controller)
How the aSMC works: •
analyzes the actual frequency spectrum and looks for characteristic patterns
•
modifies the setup accordingly
Benefit of the aSMC: •
Safety and Reliability Increase: The aSMC “understands the acoustics” and keeps the engine in the stable region
•
Discovering Hidden Reserves: The aSMC detects the actual margins and can transform them into - performance benefit - emissions benefit Unrestricted © Siemens AG 2013 All rights reserved. Page 17
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Operational Flexibility: aSMC (Example 1) 120
120
without aSMC
with aSMC 100
100
less pilot80 gas
80
Load Pilot Gas
60
NOx Accelerations
60
< 1 min 40
40
-2 ppm 20
20
0
0
18:00
18:30
19:00
17:30
19:30
17:32
17:34
17:36
17:39
With the Application of aSMC the basic Setup can be modified reduced NOx Pilot Gas is increased if necessary; usually only for a very short Time Unrestricted © Siemens AG 2013 All rights reserved. Page 18
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Operational Flexibility: aSMC (Example 2) lowest margin just when baseload is reached stabilty limit IGV: Inlet guide vane position Benefit ot the aSMC TT2: Turbine exhaust temp.
flame temperature IGV
(Inlet guide vane position)
100 % Load
TT2 offset by aSMC
2...5 min
without without aSMC aSMC
TT2
with with aSMC aSMC
(Turbine exhaust temperature)
time With the aSMC the Baseload Performance can be improved Unrestricted © Siemens AG 2013 All rights reserved. Page 19
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Summary and Outlook
With several major development steps the SGT5-4000F has been continuously improved regarding power output, efficiency and emissions. Reflecting the actual market requirements, several flexibility features have been introduced to the SCC5-4000F combined cycle power plant. The SGT5-4000F is a well established engine with proven technology, high performance, very good reliability and availability, and “best in class” regarding life time cost. Siemens will continue to develop the 4000F frame
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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. Unrestricted © Siemens AG 2013 All rights reserved. Page 21
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