Off to new frontiers: Latest Gas Turbine Power Plant ... · Off to new frontiers: Latest Gas...

Copyright © Siemens AG, 2016. All rights reserved.

World Energy Congress, Istanbul, Turkey, October 09 - 13, 2016

Off to new frontiers: Latest Gas Turbine Power Plant technology drives most environmental friendly, resource saving, affordable and reliable power generation Lothar Balling, Siemens AG, Power & Gas, Germany Gero Meinecke, Siemens AG, Power & Gas, Germany Zafer Gürsoy, Siemens AG, Power & Gas, Turkey

World Energy Congress in Istanbul, Turkey, October 09 - 13, 2016

Copyright © Siemens AG 2016. All rights reserved. 2

Abstract

This paper shows that combined-cycle power plants driven by advanced H-class GT technology

have proven to explore new terrain and to open frontiers in terms of wide-ranged and diverse mar-

ket and customer requirements. Highest power output, power density and efficiency, enhanced oper-

ational flexibility and grid support abilities, and advanced heat extraction solutions, as well as over-

all improved plant profitability and return on invest make them the power plant solution of choice

for different power generation markets worldwide. The recent projects in Germany and Egypt have

shown that the improved plant performance and abilities combined with comprehensive plant solu-

tion optimization and executional excellence will enable customers to successfully implement such

different power plant configurations as highly flexible combined heat and power plants with world

record efficiency and fuel utilization factors or, for example, large-scale base-load configurations

with highest power density and optimized cost of electricity. In any case, customers can expect to

achieve a real, quantifiable added value through optimized generation costs and at the same time set

new standards in terms of environmental friendliness and resource conservation. This makes ad-

vanced H-class gas turbine combined cycle power plants the ideal solutions to support further

growth of renewable power generation worldwide.

Keywords: combined-cycle power plants, gas turbine, H-class, advanced technology, operational

flexibility, profitability, sustainability, affordability, reliability, renewables



1. LATEST TECHNOLOGY COMBINED-CYCLE POWER PLANTS:

A GLOBAL SUCCESS STORY

Power generation markets around the world are facing constant change and the speed of change and

market diversification has also been rapidly increasing in recent years. In some regional markets, e.g.

in Europe, fossil fired and especially gas fired power generation is under pressure from the massive

growth of subsidized renewable power generation and declining electricity feed-in prices. At the same

time, regulators, grid operators and utilities are scrambling for generation solutions to cover residual

load and provide backup for fluctuating renewable infeed and to increase fuel utilization rates to

reduce fuel consumption and CO2 emissions. In other regions, e.g. in Asia, Middle East and Northern

& Central Africa, national economies and along with it local power generation industries are still

growing. Here market players face the challenge to quickly build up a sustainable power generation

landscape, often within limited national investment budgets and to satisfy an ever growing electricity

demand triggered by population and economic growth, industrialization and urbanization.

In this dynamic and diverse market environment, combined-cycle power plants (CCPP) driven by

advanced H-class gas turbine technology have gained significant market share over the last years

and have firmly established themselves globally as advanced technology carriers and enable suc-

cessful power plant projects in a wide range of applications and plant configurations. The gas tur-

bine of the Ulrich Hartmann power plant unit in Irsching, Germany was the first of its kind to be

installed anywhere in the world by Siemens, establishing a new advanced gas turbine technology

and performance class with world records for efficiency and power density in 2011. It had already

undergone extensive testing as a prototype prior to entering commercial operation, producing excel-

lent results. Siemens has since sold about 80 H-Class turbines, of which more than 20 are in com-

mercial operation since 2011. Other OEMs are now following this advanced technology path.

The characteristics and value drivers of these advanced combined-cycle power plants are:

Higher power output

Significantly improved fuel efficiency

Reduced fuel consumption

Reduced CO2 and other emissions

Overall improved conservation of natural resources

Enhanced operational flexibility

Improved integration of district heating and steam extraction applications

Advanced grid support abilities

Better economy of scale and increased power density



In the following chapters we would like to discuss two fundamentally different power generation

markets as examples: Germany and Egypt. We will show how advanced combined-cycle power

plants can be adapted to support demands and customer needs in these very diverse market envi-

ronments and to drive successful power plant projects, which provide maximized customer value to

their owners and operators.

2. FOCUS MARKET GERMANY

Looking at Germany, we do see a power generation market, which reached saturation many years

ago and where electricity demand is expected to decline in mid- and long-term due to increasing

efficiency on the consumption side in industrial, commercial and residential sectors. At the same

time renewable share in power generation is continuously growing, achieving already > 25% in

2015, and is expected to contribute more than 55% of total power production in 2030.

Hard coal

Nuclear

Gas

Oil

Others

Lignite

Renewables

WindBiomass

Solar

WasteWater

renewable part preliminary

Fig. 1 Power generation in Germany 2014, 625 TWh in total

Source: German Federal Ministry for Economic Affairs and Energy (BMWi)

This development was triggered by the energy change policy of the German Federal Government.

Renewables are not only expected to fill the production gap of nuclear power plants, which will be

shut down step by step by 2022, but are today already displacing fossil fired power generation via

low electricity production cost.



Fig. 2 Power plant structure in the Reference Forecast and Trend Scenario by energy source,

2011-2050 in GW. Source: German Federal Ministry for Economic Affairs and Energy (BMWi)

According to the reference forecast and most likely scenario, installed generation capacity of Ger-

man power plants is expected to rise at a low although steady rate due to further expansion of solar

and wind power.

At the same time, generation from coal-fired plants is going to be reduced continuously by phasing

out old, inefficient generation. The speed of decrease mainly depends on further political decision

and on the value of CO2. This will most probably influence the growth of gas fired power generation

in large, medium or small scale beyond 2020 with the goal to cover residual load and to provide

back-up capacity for the fluctuating and not fully predictable renewable power generation.

High ramps High power output

Fig. 3 Challenging energy market in Germany: February 2016

Source: Fraunhofer ISE, last update: 2016-02-20 23:14



The figure above shows the volatile and in part unpredictable nature of renewable power infeed. In

the selected time period in February 2016 everything was possible between 0 and 40 GW productive

capacity, about 50% of the installed renewable capacity. This means that fossil fired power plants

need to cover the resulting residual load between demand and renewable infeed and also need to

function as backup for unforeseen events like clouds or calms and renewable generation prediction

errors. These situations call for fast starting, highly flexible power plants, which are able to load

follow the changing residual load curve rapidly and which are large enough to provide the necessary

generation capacities with high efficiency, highest power density and lowest CO2 footprint. Ad-

vanced gas turbine technology CCPPs are the ideal partners for renewables to do this job.

2.1. H-class technology is the key to successful cogeneration projects

A major application for gas turbine based power plants in Germany is combined heat and power

(CHP) projects – also termed cogeneration. The importance of CHP plants for the German power

generation market is highlighted by the current market forecast that 2 out of 3 new built large com-

bined-cycle power plants are expected to be combined heat and power configurations in the next

years. In a CHP plant a part of the steam is extracted at suitable steam conditions and used as pro-

cess steam, e.g. for industrial or chemical processes or for district heating. Although electricity pro-

duction is going down a little bit in a CHP plant, because steam flow through the steam turbine is

reduced, the overall fuel utilization rate of a CHP plant considering electricity and heat production is

considerably higher compared to conventional power plants in condensing mode. With electrical

efficiency higher than 61% and an overall fuel utilization efficiency in cogeneration of up to 85%,

the carbon footprint of a modern H- class combined-heat and power plant with an output of 600MW

will always have a markedly lower footprint, higher electrical efficiency and lower emissions com-

pared to a highly distributed generation setup. Initial power infeed to compensate for grid fluctua-

tions is also available within five minutes after startup command when the gas turbine synchronizes

with the grid. The rotating mass of the large scale unit alone is an essential factor to grid stability.

The inertia of the rotor of a 400-ton gas turbine combined with that of a coupled steam turbine and

generator at 3,000 revolutions per minute dampens frequency fluctuations in the system. Combined

heat and power generation provides further leverage for optimizing fossil fuel utilization and there-

by reducing emissions. Many independent organizations such as the International Energy Agency

(IEA) advocate cogeneration, and Germany's Federal Government would also like to see about one

quarter of net controllable power generation in Germany coupled with heat production by 2020.

Germany's amended Combined Heat and Power Act of 2016 now supports cogeneration plants with

outputs exceeding 2MW. This applies up to a plant's 30,000th hour of full-load operation. The

change from a maximum time period for subsidization to the number of operating hours takes into



account the reduced operating times of combined-cycle power plants in their new role, thereby

providing additional incentives for investment.

2.1.1. Showcase CHP: the “Fortuna” combined-cycle unit at

Düsseldorf’s Lausward Power Station

The new combined heat and power plant “Fortuna” developed by Stadtwerke Düsseldorf and exe-

cuted in cooperation with Siemens at Lausward Power Station in Düsseldorf's inland harbor is a

cutting edge combined-cycle power plant with performances far exceeding those customarily

achieved by power generating units of this type.

By using innovative technologies, state-of-the-art engineering and the pooled expertise for optimum

power plant solutions, the project partners have ensured that environmentally friendly electric power

and district heat can be generated most economically for a low-carbon future under the new CHP

scheme – and in doing so have set three new world records.

Highest electrical power generating density– The centerpiece of the power plant is a single Sie-

mens model SGT5-8000H gas turbine. Together with the downstream steam turbine of Siemens

SST5-5000 series, these combined cycles deliver 603.8MW of net electrical generating capacity out

of the single generator in between – a level unmatched by any other single unit combined-cycle

plant in the world.

Highest efficiency – Fortuna's 61.5% proven electrical net efficiency exceeds even the previous

world record of 60.75% set by the Ulrich Hartmann combined-cycle unit at Irsching Power Station

in southern Germany. A triple-pressure Benson® steam generator that produces steam to tempera-

tures of up to 600°C at 170 bar and further innovations in the cycle makes this high electric efficien-

cy rating possible.

Best use of waste heat – To supply the city of Düsseldorf with district heat, steam is extracted from

three different steam turbine sections in volumes of up to 300MW of thermal energy in combined-

cycle operation – the most thermal energy extracted from a single power plant unit anywhere in the

world. The plant's high electrical efficiency combined with its efficient use of heat generated in the

power production process increases fuel efficiency of the natural gas in this case to around 85%.

The implementation of the new high-efficiency combined-cycle power plant in Düsseldorf presents the

solution to the task of substantially expanding the city's network for environmentally friendly and

convenient district heating.



“Fortuna” Düsseldorf SCC5-8000H 1S

Electrical generating

capacity 603.8 MWel

net

Efficiency 61.5% net

Gas turbine SGT5-8000H

Steam tur-bine SST5-5000

Generator SGen5-3000W

District heat extraction 300 MWth

Overall fuel efficiency approx. 85%

Fig. 4 Key facts: “Fortuna” Düsseldorf CHP power plant

The project for "Expanding the district heating grid on the west bank of the Rhine River at Düsseldorf"

kicked off already in October 2011 by installing the piping network in the city's districts of Heerdt and

Lörick – where one of the most modern office building complexes in Germany has been built, in terms

of efficiency and environmental compatibility – and further expansions are to follow. Infrastructure

and spatial conditions at the power plant site also enable the economical erection of a large heat

storage facility that will significantly increase the use of thermal energy produced by the combined-

cycle plant for cogeneration purposes. Stored cogeneration heat can then be fed to the grid when the

combined-cycle unit is not in operation. Integrating this large industrial facility into the center of a

major city also succeeded because importance was placed on harmonic architecture and minimal

emission of noise and other pollutants. A design competition was held to ensure the facility's

architecture was optimally integrated into the surrounding environs, which produced the winning

design created by the architectural firm kadawittfeldarchitektur. The building complex not only

enhances the cityscape, but also embraces and communicates the pioneering nature of the facility. One

particular highlight is the large "City Window" that faces the center of the city and encloses portions

of the facility in glass. Special design features ensure a high level of protection for birds. Visitors take

an elevator to reach a 45-meter-high viewing platform.

Compared to the average plant emissions of all coal-fired power plants within the European Union, a

natural gas-fueled combined-cycle power plant operating at 61.5 percent efficiency for 3,800 operating

hours cuts carbon dioxide emissions by some 1.6 million tons. This is equivalent to the emissions of

800,000 new automobiles, each clocking 15,000 kilometers a year. A forest covering some 160,000

hectares - corresponding to the area of London - would be needed to compensate for this quantity of

HRSG: BensonTM

3Pr/RH 600 °C/170 bar

Gas Turbine: SGT5-8000H

Steam Turbine: SST5-5000Multi Purpose Building incl. District Heating

Steam ExtractionHeating Condensers

Transformers

District Heating Pipelines

Generator: SGen5-3000W

ArchitectualHighlight(City Window to Center of Duesseldorf)



CO2. Even compared to the most modern combined-cycle power plants fitted with Siemens F-Class

gas turbines, that 61.5% figure represents savings of 6,700 tons of natural gas fuel and 18,500 tons of

CO2 emissions, every year.

Fig. 5 Architectural highlight: the “Fortuna” combined-cycle unit at Düsseldorf’s Lausward

Power Station. Source: kadawittfeldarchitektur

In district heating operation emissions sink even further, to 230 grams per kilowatt-hour (g/kWh)

equivalent. The design is thus sustainable and ecological, and contributes significantly towards the city

of Düsseldorf's ambitious climate protection goals of achieving climate and thus carbon neutrality by

the year 2050, which for Düsseldorf means reducing carbon dioxide emissions to two tons per capita.

2.2. Operational flexibility enables power plant dispatchability and profitability

Fossil fuel power plants will continue to play an important role in the energy mix of the future. Our

highly efficient combined-cycle power plants and cogeneration plants demonstrate that climate pro-

tection and fossil fuel power generation can go hand in hand. These plants are used when available

wind and solar power is inadequate. Ultimately, all of us, and especially our industries, rely on con-

tinuous, uninterrupted supply of electric power and need power plants that unite a number of fun-

damental characteristics: They must be highly efficient, environmentally compatible, economical

and - in particular - flexible. In the Fortuna power plant unit at Lausward Power Station a broad

range of Siemens technologies were introduced to enable the project to meet this requirement for the

greatest possible flexibility and thereby offer the customer true added value over conventional solu-

tions. Below are presented the various technologies and solutions implemented in Lausward's Fortu-

na unit that enable this flexibility. All noted results and performance values have been tested and

validated in operation.

Fast Starting (hot and warm Co-Start)

Our Co-Start technology enables plant operators to start their units quickly and efficiently under

hot-start conditions, i.e. to re-start units after a period of shutdown typically lasting eight hours or



less. We consequentially reduce fuel costs during the startup phase and increase plant responsive-

ness to rapidly changing market conditions, enabling plant operators to start units rapidly and pre-

cisely at that point in time when favorable market conditions are effective. We succeed in shortening

startup times under hot-start conditions by starting the gas and steam turbines simultaneously, con-

trary to conventional startup procedures for combined-cycle units. The gas turbine starts and runs

up, increasing its output at the steepest possible gradient right up to full load without waiting for

staggered startup of the steam turbine, as customarily practiced. The new hot-start procedure with

this Co-Start solution is governed by optimized instrumentation and controls in the DCS system.

Warm starts, meaning unit re-start after a weekend shutdown lasting typically up to 48 hours, have

also been accelerated by using our Co-Start technology. The improved startup procedure is basically

achieved by implementing the same technical measures and modifications of the startup process as

for hot starts, the only difference being the different temperature and pressure conditions in the heat

recovery steam generator considered by the instrumentation and control system after the longer pe-

riod of shutdown. Despite extensive acceleration of these startup processes, component service life

is not adversely impacted.

Plan

t Loa

d

Start-up Time

Co-Start

hot

< 25 min

Conventional start

50 min

Start-up Time

Plan

t Loa

d

Co-Start

warm

90 min.

45 min.

ConventionalStart

Fig. 6 Hot Co-Start Warm Co-Start

The verification and validation of the performance improvements enabled by Co-Start technology at

the Fortuna unit of Lausward Power Station showed that run-up time for hot starts was drastically

shortened from the customary 50 minutes to under 25 minutes. Significant fuel savings were

achieved by raising efficiency during startup, which resulted in reduced CO2 emissions and

improved unit cost-effectiveness and thus profitability thanks to lower fuel costs. Material stress test

results showed reduced fatigue stressing of the steam turbine. The overall lower plant startup costs

lead to more operating hours due to increased plant demand and capacity utilization by the load

distributor.



Increasing load change gradients (Flex-Ramp)

Enhanced power plant flexibility involves not just fast startup procedures: load change gradients

during load operation (meaning the speed at which unit output can be changed) should also be as

high as possible in a flexible, rapidly responsive power plant. We achieve this by using our Flex-

Ramp technology. The load-change gradient of a combined-cycle power plant is determined by the

combined ramping speeds of the gas turbine and steam turbine.

In order to achieve the highest possible overall gradient, the gas turbine load is changed at the highest

possible and technically allowable gradient. And when a rapid drop in power output is desired, ramp-

ing down the steam turbine load is extensively accelerated with the aid of Flex-Ramp. This technolo-

gy increases the load change gradient of a combined-cycle power plant unit by 20MW per minute over

and above the gradient of the gas turbine. As a result of these measures, the Fortuna unit at Lausward

Power Station is able to run upward and downward load ramping at 55MW per minute.

Plan

t Loa

d

Operating Time

~ 40%.

5 min

3 min

5 min

11 min 11 min

Flex-Ramp

+20 MW/min

Baseline CC35-40 MW/min

3 min

Fig. 7 Flex-Ramp

These improvements enable power plant operators to enhance their participation in the secondary

reserve market and increase the cost-effectiveness and thus profitability of their units thanks to in-

creased revenue. Operators can also increase the capacity utilization and operating hours of their

units, as the load distributor will more frequently turn to flexible, rapidly responding power plants

with high load change gradients.

Impacts of increased operating flexibility

All of the solutions described above contribute to improving profitability, lowering the variable gen-

erating costs and emissions of power plants. As in liberalized electricity markets like Germany's

those power plants with the lowest variable power production costs are granted first access to the

grid in accordance with the merit order, all in all these new technologies will gain a power plant

more advantageous positioning in the merit order curve against high emission coal plants. The pref-

erential grid access and more frequent demand from the grid operator result in more operating

hours, better capacity utilization and optimized power production, and ultimately improves total

emission situation.



3. FOCUS MARKET EGYPT

The power generation market in the Middle East and North Africa is currently one of the largest and

most active in the world. Providing energy to fuel domestic economic and population growth re-

mains a key priority for the region particularly in Saudi Arabia, Kuwait, the UAE and Egypt. The

power generation in this region is not only supplying electricity, but is also powering water desalina-

tion (reverse osmosis and thermal desalination) and thus directly influencing the availability of po-

table water in the region. More generation, including more gas fired generation is needed to achieve

these goals. Energy demand in this region is continuously increasing and the expectation of contin-

ued growth at the current pace is leading some countries to re-think their basic energy mix policies.

Power plant projects with up to 3-4 GW per project are common in this region. These projects are

significantly larger than in any other region worldwide and the successful execution of these mega

projects become both technically and logistically an increasingly important factor for the Middle

East and North African power generation market. Any delay in project execution implies an imme-

diate threat on the security of supply. The future power generation market development in Egypt is

characterized by the constant growth of power generation as well as installed capacity driven by

population and economic growth, in line with the overall market development trends in the region as

discussed above. In the next decade an annual electricity production growth rate of around 4.5% and

the more than doubling of current installed capacity are expected. 80% of power generated is cur-

rently produced from natural gas. This share is expected to remain stable in the future, making gas

fired power plants the key elements of the energy landscape in Egypt now and tomorrow.

Power Generation 2014-30[TWh/a]

139190 249 291

Nuclear

Oil

Coal

4.5%

Gas

Wind

2030

9

Renewables363

2025

180

26

13

15304

16

2020

247

28

2014 Fig. 9 Egypt Power generation market 2014-2030, Source: Siemens

Egypt’s energy policy is characterized by a liberalized but government driven energy sector with long-

term successful international collaboration. In the power sector current mega projects for power plants

and grid extension are needed to stabilize power supply and to enable economic growth. Available

power generation capacity is currently directly absorbed by demand. Recent gas discoveries in the

Mediterranean may allow Egypt to return to a net energy export country soon and a limited LNG im-

[GW]

13

24

34

6 68 7

8

5 16

15

CCPP(incl. IGCC)

SCPP

SPP

Nuclear

Hydro

Solar

Wind

Engines

2030

82

3

Cap. Add. 15 - 30

54

Ret. 15 - 30

-93

2014

37

4

3

4

Installed Capacity 2014-30



port infrastructure is being build-up. Limited national budgets or financing constraints in developing

countries are calling for cost effective power generation solutions, which means that not only the low

specific investment of large plants due to their economy of scale is in focus, but also highest possible

power density. High environmental standards are also an important aspect when it comes to ensuring

and unlocking necessary international funding and financial aid for such large international power

plant projects. And finally, project execution speed is of the essence as every MW power generation

capacity going online will immediately help to further develop the country and its economy. Review-

ing the above mentioned market requirements it becomes clear that H-class advanced GT technology

combined-cycle power plants are the ideal solution to meet these requirements.

3.1. Showcase: Egypt Mega Projects

Together with Egypt’s people, Siemens is building a foundation for progress to unlock Egypt's vast

potential with the three mega combined cycle projects Burullus, New Capital and Beni Suef and

further power generation and distribution infrastructure. Siemens has signed contracts worth €8 bil-

lion for high-efficiency natural gas-fired power plants and wind power installations that will boost

Egypt's power generation capacity by more than 50 percent compared to the currently installed base.

Fig. 10 Egypt Mega projects, Source: Siemens

The projects will add an additional 16.4 gigawatts (GW) to Egypt's national grid to support the

country's rapid economic development and meet its growing population's demand for power. To-

gether with local Egyptian partners Elsewedy Electric and Orascom Construction, Siemens will

supply on a turnkey basis three highly efficient and environmental friendly natural gas-fired com-

bined cycle power plants, each with a capacity of 4.8GW, for a total combined capacity of 14.4GW.



Each of the three power plants –- Beni Suef, Burullus and New Capital – will be powered by eight

advanced Siemens H-Class gas turbines, selected for their highest power density, record-breaking

efficiency and subsequently low emissions. In addition, Siemens is also supplying about 600 wind

turbines for 12 wind farms with another 2 GW clean power generation spread over the country and

adds value and education to the people by creating more jobs in the generation facilities and also in

blade factories.

Siemens has been doing business in Egypt since 1859 and has maintained a continuous presence in

the country since opening its first office in Cairo in 1901. The company's technology has been im-

plemented in the Attaka, Nubaria, Talkha, Damietta, Sidi Krir, Cairo West, Ayoun Mousa, Midelec

and El Kureimat power plants. The three mega fossil plants will add power to the grid in stages.

Once completed, the three power plants will be the largest H-class plants in the world providing

efficient and clean power generation into the region.



4. CONCLUSION

Combined-cycle power plants using most advanced H-class GT technology provide highest power

output, power density and efficiency, enhanced operational flexibility and grid support abilities. The

possibility to power advanced heat extraction solutions, as well as overall improved plant profitabil-

ity and return on invest make them the preferred power plant solution for a wide range of customer

and market requirements in different power generation markets worldwide. Improved plant perfor-

mance and abilities combined with comprehensive plant solution optimization and executional ex-

cellence will enable customers to successfully implement such different power plant configurations

as highly flexible combined heat and power plants with world record efficiency and fuel utilization

factors or, for example, large-scale base-load configurations with highest power density and opti-

mized cost of electricity. Best examples for this wide and flexible application and solution range are

the recent combined-cycle power plant projects in Korea,Germany and Egypt. Customers will

achieve a real, quantifiable added value through optimized generation costs and at the same time set

new standards in terms of environmental friendliness and resource conservation. Advanced H-class

gas turbine combined cycle power plants are the ideal solutions to satisfy an increasing power gen-

eration demand in a sustainable, resource-saving and affordable way and to support further growth

of renewable power generation worldwide.



5. REFERENCES

[1] Schlesinger, M., Lindenberger, D., Lutz, C. 2014. Development of Energy Markets – Energy

Reference Forecast. Project No. 57/12, Study commissioned by the German Federal Ministry of

Economics and Technology, Berlin

[2] Fraunhofer Institue for Solar Energy Systems ISE. 2016. German Renewable Energy

Production, update 2016-02-20 23:14, https://www.energy-charts.de

https://www.energy-charts.de/



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