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
© Siemens Protection AG 2009. noticeAll / Copyright rights reserved. notice
Outline
Page 2
1.
Introduction
2.
Development History & Operating experience
3.
Emission reduction
4.
Extension of Engine life cycle
5.
Maintenance Down Time reduction
6.
Maintenance cost reduction
7.
Operation Improvement
8.
Ongoing SGT-600 Upgrades and Improvements
9.
Summary
VGB 2013, Friedrichshafen, Germany
Dr. V. Navrotsky
Siemens Industrial Turbomachinery AB, Finspong, Sweden
Siemens Industrial gas turbine range
Utility Turbines
SGT5-8000H
375
SGT5-4000F
287
Industrial Turbines
SGT6-8000H
266
SGT6-5000F
SGT5-2000E SGT6-2000E SGT-800 SGT-750 SGT-700 SGT-600 SGT-500 SGT-400 SGT-300 SGT-200 SGT-100
198 168 113 47/50 36 31/33 25 19 13 8 7 5
(MWe)
Siemens offer a wide power range of Gas Turbines for Industrial and O&G markets Page 3
VGB 2013, Friedrichshafen, Germany
Dr. V. Navrotsky
Siemens Industrial Turbomachinery AB, Finspong, Sweden
SGT-600 Latest Design Features General Design
Two shaft Gas Turbine 10 stage compressor (PR=14) Two stage compressor turbine Two stage power turbine
The design for PG is the same as for a MD
Page 4
VGB 2013, Friedrichshafen, Germany
Welded compressor rotor, Two variable guide vanes, Two bleeds after stage 2 and 5, All blades are coated (titanium blade 1) Abradable coating on all stator rings 2:nd generation Dry Low Emission Comb. Integrated by-pass system
Dr. V. Navrotsky
Siemens Industrial Turbomachinery AB, Finspong, Sweden
Outline
Page 5
1.
Introduction
2.
Development History & Operating experience
3.
Emission reduction
4.
Extension of Engine life cycle
5.
Maintenance Down Time reduction
6.
Maintenance cost reduction
7.
Operation Improvement
8.
Ongoing SGT-600 Upgrades and Improvements
9.
Summary
VGB 2013, Friedrichshafen, Germany
Dr. V. Navrotsky
Siemens Industrial Turbomachinery AB, Finspong, Sweden
SGT- 600 Key Core Engine Features and Experience, Data - March 2013
SGT-600 first introduced 1986
Fleet details
Technical details Mechanical Drive
34,100 bhp
Electrical Output
24.8 MW
Efficiency (PG/MD)
34.2%/ 35.1%
Exhaust Mass flow
80.4 kg/s
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 Reliability: 99.5% > 3 600 starts Availability: 96.5%
The SGT-600 evolution Sulzer Escher Wyss (CH)
1975
VGB 2013, Friedrichshafen, Germany
Uprating
1980
1985
1990
1995
2000
2005
#1 Package
2rd generations DLE emission:
Page 6
Floater Package
DLE
Exhaust Temperature 543 °C NOx on gas: < 25 ppmV @15% O2 NOx on liquid: < 42 ppmV @15% O2
#2 Package
Transfer – SEW to ABB STAL AB* (SE) Siemens
Prototype testing
4 units by Sulzer
Transfer
300+ units by Siemens
SGT-600 Specification
Dr. V. Navrotsky
Siemens Industrial Turbomachinery AB, Finspong, Sweden
Outline
Page 7
1.
Introduction
2.
Development History & Operating experience
3.
Emission reduction
4.
Extension of Engine life cycle
5.
Maintenance Down Time reduction
6.
Maintenance cost reduction
7.
Operation Improvement
8.
Ongoing SGT-600 Upgrades and Improvements
9.
Summary
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)
Combustor Bypass system
3rd generation DLE (MGT)
MGT DLE technology is effective, simple & reliable (simple principle with no moving parts or staging) Page 8
VGB 2013, Friedrichshafen, Germany
Dr. V. Navrotsky
Siemens Industrial Turbomachinery AB, Finspong, Sweden
Outline
Page 9
1.
Introduction
2.
Development History & Operating experience
3.
Emission reduction
4.
Extension of Engine life cycle
5.
Maintenance Down Time reduction
6.
Maintenance cost reduction
7.
Operation Improvement
8.
Ongoing SGT-600 Upgrades and Improvements
9.
Summary
VGB 2013, Friedrichshafen, Germany
Dr. V. Navrotsky
Siemens Industrial Turbomachinery AB, Finspong, Sweden
Life Cycle Extension Program Life Cycle extension – LTA / LTE
Life Time Assessment
SGT-600 Maintenance Schedule with LTA & LTE LTE
Performed at 80,000 EOH
Level “E“ + LTA Level “D“
Level E inspection, with analysis and evaluation
Level “C“ Level “B“
Status determination of major components: Non-destructive Destructive tests
Level “A“ Operation Maintenance 10‘
20‘
30‘
40‘
50‘
60‘
70‘
80‘
90‘
100‘ 110‘ 120‘ 130‘ 140‘ 150‘ 160‘
EOH x 1000
Life Time Extension
120,000 EOH level C inspection +:
Cost optimization of operation Beyond 120,000 EOH
Recommended replacements as agreed with customer Upgrade packages as agreed with customer
Tailored scope of repair & replacement parts for LTE Page 10
VGB 2013, Friedrichshafen, Germany
Dr. V. Navrotsky
Siemens Industrial Turbomachinery AB, Finspong, Sweden
Life Cycle Extension Life Cycle extension = LTA + LTE Combustion chamber
Compressor turbine vanes # 1 & 2
Compressor turbine blades # 1
Power turbine blades # 3
Tailored scope of repair & replacement parts for LTE Page 11
VGB 2013, Friedrichshafen, Germany
Dr. V. Navrotsky
Siemens Industrial Turbomachinery AB, Finspong, Sweden
Life Cycle Extension Rotor condition examination Weld examination
Balancing holes
Blade grooves Stop holes
Centre and bolt holes Internal radius transitions
Replica tests Balancing holes
Centre holes
Page 12
VGB 2013, Friedrichshafen, Germany
Dr. V. Navrotsky
Blade grooves
Siemens Industrial Turbomachinery AB, Finspong, Sweden
Outline
Page 13
1.
Introduction
2.
Development History & Operating experience
3.
Emission reduction
4.
Extension of Engine life cycle
5.
Maintenance Down Time reduction
6.
Maintenance cost reduction
7.
Operation Improvement
8.
Ongoing SGT-600 Upgrades and Improvements
9.
Summary
VGB 2013, Friedrichshafen, Germany
Dr. V. Navrotsky
Siemens Industrial Turbomachinery AB, Finspong, Sweden
Maintenance Down Time reduction Extension of Maintenance Intervals -> 3 overhauls instead of 5
5–2 = 3 inspections
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 Level “C”
Major Overhaul
Level “B”
Hot Section Inspection
Level “A”
Borescope
Operation Maintenance 10 20
30
40
50
60
70
80
90 100 110 120
Eq. Op. Hrs x 1000
The Extension of Maintenance Intervals can improve the availability by up to ~ 1 % Page 14
VGB 2013, Friedrichshafen, Germany
Dr. V. Navrotsky
Siemens Industrial Turbomachinery AB, Finspong, Sweden
SGT-600 Maintenance Down time reduction Development of Maintenance tools
Compressor blade dismantling tool
Gearbox tool
Gas Generator extraction tool
.
25% inspection time reduction 80% blades saving improves safety
reduces down time improves safety
reduces down time simplifies work improves safety
SGT-600 Maintainability improvement results in reduction of Maintenance duration and cost Page 15
VGB 2013, Friedrichshafen, Germany
Dr. V. Navrotsky
Siemens Industrial Turbomachinery AB, Finspong, Sweden
Outline
Page 16
1.
Introduction
2.
Development History & Operating experience
3.
Emission reduction
4.
Extension of Engine life cycle
5.
Maintenance Down Time reduction
6.
Maintenance cost reduction
7.
Operation Improvement
8.
Ongoing SGT-600 Upgrades and Improvements
9.
Summary
VGB 2013, Friedrichshafen, Germany
Dr. V. Navrotsky
Siemens Industrial Turbomachinery AB, Finspong, Sweden
Current repair status SGT-600 Repairs according to maintenance plan & on condition 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 Current scope of repair on condition: Compressor abradable ring recoating Turbine blade #1 repair Rotor seal edge repair Honeycomb seals #1, #2 & #3 repair Compressor blade & vane recoating Siemens invest significantly into R&D development to support further increase of repair yield and reduce repair cost
Page 17
VGB 2013, Friedrichshafen, Germany
Dr. V. Navrotsky
Siemens Industrial Turbomachinery AB, Finspong, Sweden
Current repair status SGT-600 Repairs according to maintenance plan & on condition Combustion Chamber Honeycomb seals Comp, recoat abradable rings
Comp, blade & vane recoating
Sealing edge replacement
1st Vane
Turb blade #1
2nd Vane
SGT-600 repair as a part of Maintenance Program to reduce maintenance cost Page 18
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 Blade #1
Honeycomb 1 Vane #2
Vane #1
Honeycomb 2
Combustor
Page 19
VGB 2013, Friedrichshafen, Germany
Honeycomb 3
Dr. V. Navrotsky
Siemens Industrial Turbomachinery AB, Finspong, Sweden
DLE Combustor repair Typical repair actions: 1. Incoming inspection & assessment 2. Cut combustor according to dwg. 3. Strip coating by grit blasting 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
Typical repair options: A. Replacement of Heat Shield B. Replacement of inner and outer liner C. Weld repair of burner cone D. Replacement of by pass sleeves E. Cleaning of carbonized oil in burners
Only part of available repair options are required
Page 20
VGB 2013, Friedrichshafen, Germany
Dr. V. Navrotsky
Siemens Industrial Turbomachinery AB, Finspong, Sweden
Turbine GV #1 Typical repair actions: Incoming inspection & registration Strip coating, chemical Inspect & assessment Blend to remove oxidation Solution heat treatment Weld repair as required Floride Ion Cleaning (FIC) Braze repair as required Restore dimensions and gas path shape Recoat according to spec Final insp. incl flow properties
Crack in trailing edge
Oxidation of parent material
Page 21
VGB 2013, Friedrichshafen, Germany
Dr. V. Navrotsky
Siemens Industrial Turbomachinery AB, Finspong, Sweden
Turbine GV #2 Typical repair actions: • Incoming inspection and registration • Strip coating, chemical • Inspect and assessment • Blend to remove oxidation • Solution heat treatment • Weld repair as required • Floride Ion Cleaning (FIC) • Braze repair as required • Restore dimensions and shape • Recoat according to spec • Final insp. Incl. flow properties
Crack in key slot
Oxidation of sealing fins
Page 22
VGB 2013, Friedrichshafen, Germany
Dr. V. Navrotsky
Siemens Industrial Turbomachinery AB, Finspong, Sweden
Honeycomb repair Typical repair actions: 1. Incoming inspection and registration 2. Clean part by light grit blast 3. Remove old HC 4. Inspect and assessment 5. Braze new HC in place 6. Machine HC to final height 7. Final inspection
Page 23
VGB 2013, Friedrichshafen, Germany
Dr. V. Navrotsky
Siemens Industrial Turbomachinery AB, Finspong, Sweden
Compressor abradable ring repair Typical repair actions: 1. Incoming inspection and registration 2. Clean part by light grit blast 3. Remove old coating by machining 4. Inspect 5. Apply Nickel plating 6. Apply abradable coating 7. Machine to final dimension 8. Final inspection
Page 24
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. Non-destructive Inspections Infrared Thermography 3D X-ray Tomography
Laser Cladding Technology
Laser Sintering
Page 25
VGB 2013, Friedrichshafen, Germany
Dr. V. Navrotsky
Siemens Industrial Turbomachinery AB, Finspong, Sweden
Outline
Page 26
1.
Introduction
2.
Development History & Operating experience
3.
Emission reduction
4.
Extension of Engine life cycle
5.
Maintenance Down Time reduction
6.
Maintenance cost reduction
7.
Operation Improvement
8.
Ongoing SGT-600 Upgrades and Improvements
9.
Summary
VGB 2013, Friedrichshafen, Germany
Dr. V. Navrotsky
Siemens Industrial Turbomachinery AB, Finspong, Sweden
Operation Improvement & optimization From Data collection & analysis to Customer Value Generation
Expert Diagnostics Centers
Operating Data + Specialty Monitor
Network
Power Plant
Worldwide Siemens Network for Data Exchange
Team
Advanced diagnostic Engineering Know-how: Reports tools & techniques for: Interpretation & Diagnostics Monitoring of engine conditions Data assessment Data collection / processing Development of Analysis of limit values recommendations for future Info & deviation from operations, repairs and / or Access modernizations normal behaviour
Customer Relationship Management
Analysis Monitoring
Offline Diagnostics
Online Diagnostics Online Diagnostics 27 27 Page
VGB 2013, Friedrichshafen, Germany
Dr. V. Navrotsky
Siemens Industrial Turbomachinery AB, Finspong, Sweden
Outline
Page 28
1.
Introduction
2.
Development History & Operating experience
3.
Emission reduction
4.
Extension of Engine life cycle
5.
Maintenance Down Time reduction
6.
Maintenance cost reduction
7.
Operation Improvement
8.
Ongoing SGT-600 Upgrades and Improvements
9.
Summary
VGB 2013, Friedrichshafen, Germany
Dr. V. Navrotsky
Siemens Industrial Turbomachinery AB, Finspong, Sweden
Ongoing SGT-600 Upgrades and Modification supports continuous product and services improvement Description
Baseline
Target
Increased power at hot ambient temperatures, 18.3 MWMD 19.8 MWMD 45OC Increased efficiency at hot ambient 31.9 %MD 32.4 %MD temperatures, 45OC AEV: Reduced NOx Emissions at 100%-50% 24,4-30 15 load (gas fuel) ppm ppm Increased time based TBO, without reduced 30’ EOH 34’ EOH . T7-limit at hot ambient conditions. Increased cycle based TBO, without reduced 600 1200 T7-limit at hot ambient conditions.
36
60
52
60
27
60
52
60
Focus on further Emission & Downtime reduction, Flexible operation & life extension (including cyclic life) Page 29
VGB 2013, Friedrichshafen, Germany
Dr. V. Navrotsky
Siemens Industrial Turbomachinery AB, Finspong, Sweden
Outline
Page 30
1.
Introduction
2.
Development History & Operating experience
3.
Emission reduction
4.
Extension of Engine life cycle
5.
Maintenance Down Time reduction
6.
Maintenance cost reduction
7.
Operation Improvement
8.
Ongoing SGT-600 Upgrades and Improvements
9.
Summary
VGB 2013, Friedrichshafen, Germany
Dr. V. Navrotsky
Siemens Industrial Turbomachinery AB, Finspong, Sweden
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 31
VGB 2013, Friedrichshafen, Germany
Dr. V. Navrotsky
Siemens Industrial Turbomachinery AB, Finspong, Sweden
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.
32 Page 32
VGB 2013, Friedrichshafen, Germany
Dr. V. Navrotsky
Siemens Industrial Turbomachinery AB, Finspong, Sweden
Thank you for your attention!
Copyright © Siemens AG 2008. 33 Page 33
VGB 2013, Friedrichshafen, Germany
Dr. V. Navrotsky
Siemens Industrial Turbomachinery AB, Finspong, Sweden
Operation with varying Wobbe-index (WI)
Fully released; Conventional Fully released; DLE Sales approved case by case
Low Calorific Value (LCV)
10
20
40
35
25
Medium Calorific Value (MCV)
30
55
‘’Normal’’ Pipeline NG
40 Wobbe Index (MJ/Nm³)
50
78
High Calorific Value (HCV)
60
70
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 34
VGB 2013, Friedrichshafen, Germany
Dr. V. Navrotsky
Siemens Industrial Turbomachinery AB, Finspong, Sweden
Repair as part of maintenance concept
New & Clean 0 EOH CT Blade 1, Set #1
Level B 20’ EOH
Level C 40’ EOH
Level D 60’ EOH
Level E 80’ EOH
NEW
CT Blade 1, Set #3
NEW
NEW
CT Blade 2, Set #2
PT Blade 3, Set #1
NEW
NEW
PT Blade 3, Set #2
NEW
PT Blade 3, Set #3
Comb. Ch., Set #1
NEW
NEW
Comb. Ch., Set #2
CT Vane 1, Set #1
RECONDITIONED NEW
NEW
CT Vane 1, Set #2
RECONDITIONED
RECONDITIONED NEW
RECONDITIONED RECONDITIONED
NEW NEW
CT Vane 2, Set #2
Page 35
RECONDITIONED RECONDITIONED
CT Vane 1, Set #3
CT Vane 2, Set #1
120’ EOH
NEW
CT Blade 1, Set #2
CT Blade 2, Set #1
Level B 100’ EOH
VGB 2013, Friedrichshafen, Germany
RECONDITIONED NEW
Dr. V. Navrotsky
RECONDITIOND
Siemens Industrial Turbomachinery AB, Finspong, Sweden
Current repair status SGT-600 - Repairs technology details and Repair Suppliers
Component
Weld repair
Braze rep
Striping
Coating type
TBC type
Comp. blades
No
N/A
Yes
V900
N/A
Comp. vanes
No
No
Yes
V900
N/A
Rotor seals
N/A
N/A
N/A
N/A
N/A
Abradable rings
No
N/A
Yes
Metco 307
N/A
Recotech, SW
Combustor
Yes
N/A
Yes
APS bond coat
APS
In house / Volvo Aero
Yes, replace tip
N/A
N/A
N/A
N/A
Only applicable for conv. burners, Unison, UK
Turbine Vane 1
Yes
Yes
Yes
PtAl
N/A
PAS, Ireland
Turbine Blade 1
Yes
N/A
Yes
PtAl
APS
Turbocoating, Italy
N/A
PAS, Ireland
Burners
Heat shield
Suppliers Repair in qualification CCRS, UK Repair in qualification CCRS, UK Seals replaced by caulking
Repair not qualified
Turbine Vane 2
Yes
Yes
Yes
Turbine blade 2
PtAl Repair not qualified
SGT-800 repair as a part of Maintenance Program to reduce maintenance cost Page 36
VGB 2013, Friedrichshafen, Germany
Dr. V. Navrotsky
Siemens Industrial Turbomachinery AB, Finspong, Sweden
