RussiaPower 2012_Moscow_Paper Siemens_SGT5-2000E_Richter-Rev.pdf

8/17/2019 RussiaPower 2012_Moscow_Paper Siemens_SGT5-2000E_Richter-Rev.pdf

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SIEMENS AG, RUSSIA POWER 2012 1

Russia Power 2012, Moscow

SGT5-2000E Gas Turbine - reliable, safe, and flexible power generation

Frank Richter, Siemens AGDr. Alexander Lebedev, Siemens Gas Turbine TechnologyGerhard Bohrenkämper, Siemens AGDr. Nils Herzog, Siemens AGFrank Schneider, Siemens AG

0. Abstract

Customer’s expectations are characterized by an increasing demand foroperational flexibility and the requirement to lower power generation costs.

To accommodate these requirements a gas turbine has to be robust, flexible andcost effective. An engine with a proven and reliable design should operate undervarying fuel parameters and different specific conditions.

Siemens Fossil Power Generation incorporates decades of operating experiencewith heavy-duty gas turbines based on proven technology. Application of theaccumulated know-how is being implemented for reliable, efficient, flexible andsave operation.

Due do the robust design, the Siemens SGT-2000E Gas Turbine series operatesat high levels of reliability and availability – even under challenging conditions.

This paper is focusing on the broad range of SGT-2000E applications withemphasis on the Oil & Gas industry and the operation under cold ambientconditions.

These applications require solutions with respect to safety, reliability availabilityand serviceability. Conformity to dedicated industry regulations is essential aswell.Siemens offers specifically tailored packages that cover demands of a widerange of exploitation fields either by supporting direct mechanical drive or an all-electrical drive solution.

Another feature, highlighted in this paper is the capability of the 2000E frame tooperate in an ambient temperature range far below minus 15°C.


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1. Introduction SGT5-2000E ..................................................................................3

1.1. Maturity...................................................................................................3

1.2.

Design Features .....................................................................................4

1.3. Current Applications..............................................................................6

2. Oil and Gas.........................................................................................................7

2.1. Market .....................................................................................................7

2.2. SGT5-2000E Oil and Gas Specific Capabilities ....................................8

2.2.1. Operational Capability................................................................9

2.2.1.1. Start up time ....................................................................9

2.2.1.2. Black Start Capability ...................................................10

2.2.2.

Fuel Capability ..........................................................................10

2.2.3. Service Concept .......................................................................11

3. Cold Ambient ...................................................................................................11

3.1. Market and requirements.....................................................................11

3.2. SGT5-2000E Standard Capabilities....................................................12

3.3. Power Limit Increase of the SGT5-2000E ...........................................12

3.4. SGT5-2000E Optimizations for Cold Ambient temperatures down to -40°C .......................................................................................................14

3.5. SGT5-2000E Optimizations for Cold Ambient Temperatures below -

40°C .......................................................................................................16

4. Lookout ............................................................................................................16

5. Takeaways........................................................................................................16


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1. Introduction SGT5-2000E

1.1. Maturity

The SGT5-2000E is the E class working horse of Siemens. It has been availablefor more than 30 years. During these years the SGT5-2000E has satisfieddemands of different markets as Power Generation, and Industrial- as well as Oiland Gas- applications.Key factors for this success are the continuous design improvements resulting ina unique engine maturity and the ability to respond to a broad range of specificrequirements.The SGT5-2000E proved an availability of 95%. The reliability is even higher andachieves 99%.These world class figures are based on a deployment of far more than 300

engines with around 20Mio Total EOH (Equivalent Operating Hours) in the 50Hzand 60Hz market.The SGT5-2000E is appreciated for its light-weight design enabling a broadrange of operational modes. The engine serves in continuous duty as well as incyclic duty covering peak loads, providing an excellent start up capability.The SGT5-2000E proves that it is possible to reconcile ambitious economic andenvironmental targets. Despite its high flexibility in terms of operation and fuels,the NOx and CO2 emissions of a SGT5-2000E are minimized.

Figure 1 SGT5-2000E market

Installations Worldwide

1 2 4 6

9 1 2

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Year of Initial Operation

SGT5-2000E SGT6-2000E

Installations Worldwide

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9 1 2

1 4 1

8 2 7 3

1 3 3 4

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Year of Initial Operation

SGT5-2000E SGT6-2000E


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In 2001 Power Machines and Siemens AG have concluded a License Agreementwith the right to produce and sell GTE-160 gas turbine with rated power of 157MW under documentation of V94.2 – which was a previous naming for the SGT2000E . As a result, the first power plant of Kalinigradskaya CHP-2 with CCP-450was accepted for commercial operation. As for scheme and equipmentcomposition, this plant was identical to North-West CHP plant, only instead of94.2 there were applied GTE-160 gas turbines, manufactured by LMZ underLicense from Siemens. Validation tests conducted in May, 2006, have confirmedthe GT performances specified.Now the fleet of GTE-160, produced by OJSC Power Machines and assembledby ООО Interturbo, accounts for 35 units (included 5 V94.2): in operation - 13 GTE-160 and 5 V94.2; in stage of erection at power plants - 8 GTE-160; in stage of manufacturing - 7 GTE-160, including 2 GTE-145.

1.2. Design Features

Siemens 2000E series gas turbines are single-shaft machines. They are suitableboth, as prime movers for industrial machines and for driving generators atconstant speed in base load and peak load operation. These machines can beused stand alone for peaking duty or in combined cycles and district heatapplications. They are suitable for operation with gaseous or liquid fuels.

The main design characteristics of SGTx-2000E Series turbine to easemaintenance are described below.1) Casing: Horizontally split turbine outer casings with separate vane and turbine

carriers, free to expand with temperature2) Rotor: Single shaft disc-type rotor with radial Hirth-serrations and one central

tie rod3) Compressor: 16 (50Hz) / 17 (60 Hz) stage compressor (with 0th row variable-

pitch IGV vanes, fast acting for grid frequency stabilization)4) Combustion system: Two large external silo-type combustors 2 x 8 (2 x 6 for

60 Hz) hybrid burners for 50 / 60 Hz; ceramic and metallic lining of the flametubes

5) Turbine: Four stage turbine, Si3D (Siemens innovative 3D design ) for newapparatus and service modernizations

6) Welded design for hot gas casings7) Axial exhaust for ease of combined cycle8) Two bearings only: Combined thrust and journal bearing at compressor end

(8a) and Journal bearing at turbine end (8b)9) Cold end drive


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Figure 2 SGT5-2000E Design

3

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1.3. Current Applications

The SGT5-2000E is characterized by large volume-combustion with moderateturbine inlet temperatures. The result is a very robust engine with a simple hotgas path design that allows a broad range of application.The standard fuel gas operation for the fossil power generation covers themajority of the operating fleet.Beyond this Fossil Power Generation the SGT5-2000E even supports fastgrowing non standard applications that require low BTU (British Thermal Unit)fuels. The engine has to cover problems like Lean Blow Out (LBO) and flamestabilization.The SGT 5-2000E proved within an IGCC-application (Integrated GasificationCombined Cycle) in China the ability to handle challenges as e.g. safe ignitionand the flashback risk

With liquid fuels the engine is faced to different challenges. The less the fuel isrefined, the more it is necessary to treat the fuel with respect to viscosity andcontamination. Some contaminations as sodium and potassium can be washedout of the fuel. Some other contaminations as vanadium or lead remain within thefuel and have to be treated with inhibitors. This inhibition causes ash. The enginehas to be able to deal with the ash.An increasing fleet of engines that are running the Crude Oil application provesthat Siemens has the ability to guarantee the habitual high standards withrespect to reliability and availability.

A p p l i c a t i o n

G T

V e r s i o n

T y p i c a l

F u e l s

O p

e r a t i o n

M o d e

C u s t o m

e r

S e g m e

n t

Standard Fossil Power Generation

SGTx-2000E

Standard NaturalGas, NaturalGas

Light Fuel Oil

Simple Cycle

Combined Cycle

StandardPower Generation

Base, Cycling,Peaking mode

Dual fuel

operation

SGTx-2000E (CO)

Crude Oil, HFO

Simple Cycle(CO / HFO)

CombinedCycle (HFOonly)

CO / HFOOperators

Base, Cyclingmode

SGT5-2000E (LC)

SynGas

LowBTU

IGCC Plant

IGCC

Base-, Part- load,Intermed. Cyclingwith no- or partial-air sideintegration

Dual fuel operat.

IndustrialApplications

Standard PowerGeneration (SC, CC) andPoly-Generation for Steeland Chemical Plants

Standard, LowBTU,SynGas;

Base load, Part load,Intermediate Cycling

SGTx-2000E

SGTx-2000E (CD)

SGT5-2000E (LC)

SGTx-2000E (CO)

Oil & Gas Business Applications

SGTx-2000E (CD) - asCompressor Drive

Standard, LowBTU,SynGas

LNG, GTL, LPG

Pumping of oil, gas andother liquids and gaseousmedia

Refinery applications

Direct MechanicalDrives

Compressor Drivemode.

SGTx-2000E (CD) - asGeno-Drive

SGT5-2000E (LC)


Power Generation for Oil& Gas Applications

All Electric Drive



G T

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n t


SGTx-2000E


Light Fuel Oil

Simple Cycle

Combined Cycle



Dual fuel

operation

SGTx-2000E (CO)

Crude Oil, HFO



CO / HFOOperators

Base, Cyclingmode

SGT5-2000E (LC)

SynGas

LowBTU

IGCC Plant

IGCC


Dual fuel operat.


SGTx-2000E


Light Fuel Oil

Simple Cycle

Combined Cycle



Dual fuel

operation

SGTx-2000E


Light Fuel Oil

Simple Cycle

Combined Cycle



Dual fuel

operation

SGTx-2000E (CO)

Crude Oil, HFO



CO / HFOOperators

Base, Cyclingmode

SGTx-2000E (CO)

Crude Oil, HFO



CO / HFOOperators

Base, Cyclingmode

SGT5-2000E (LC)

SynGas

LowBTU

IGCC Plant

IGCC


Dual fuel operat.

SGT5-2000E (LC)

SynGas

LowBTU

IGCC Plant

IGCC


Dual fuel operat.





SGTx-2000E

SGTx-2000E (CD)

SGT5-2000E (LC)

SGTx-2000E (CO)





SGTx-2000E

SGTx-2000E (CD)

SGT5-2000E (LC)

SGTx-2000E (CO)




LNG, GTL, LPG






SGT5-2000E (LC)



All Electric Drive





LNG, GTL, LPG







LNG, GTL, LPG






SGT5-2000E (LC)



All Electric Drive



SGT5-2000E (LC)



All Electric Drive


Figure 3 SGT5-2000E applications


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2. Oil and Gas

2.1. Market

The Oil and Gas market is being segmented into exploration and production (Upstream) supply, transport and storage (Midstream) refinery / petrochemical (Downstream)

The growing potential especially in the up- and midstream area appearssignificant due to the fact that O&G companies are expanding their values chainvertically.The change from a deployed mechanical driven compressor infrastructure to an

all electrical approach bears for the Oil and Gas companies the potential todecrease operational costs by increasing the availability. In some areas even theavailability of an own independent power supply becomes more and morecrucial. The larger the exploration fields are, the more an all electrical approachbecomes obvious. This development leads to the expectation of a growing HeavyDuty Gas Turbine market within the O&G business.

The key success factor for Oil and Gas companies is a proven design thatguarantees availability, reliability and safety operation.

The gas turbine package shall be optimized to fulfill the following requirements: selected API- (American Petroleum Institute) codes, flexible application of different fuels, application of H2S rich gases increased reliability and starting reliability, extended maintenance concept, pre-packed solution for fast erection and service island operation


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2.2. SGT5-2000E Oil and Gas Specific Capabilities

The specific capabilities, described within the following chapter, cover dedicatedrequirements of the Oil and Gas industry. However one of the most importantassets to become successful in this market is the outstanding maturity,availability and reliability and the extensive field experience of the SGT5-2000Efleet.Oil and Gas applications are often faced to challenging climate conditions anddifficult EHS- (Environment Health and Safety) requirements as e.g. a toxicambient atmosphere. Even the transport infrastructure and accessibility of theexploration fields are usually rather limitedThe gas turbine package is provided as pre-packaged solution, aiming to beinstalled, commissioned and serviced on the site in very short interval.

Figure 4 Prepackaged SGT5-2000E for the Oil&Gas industry


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2.2.1. Operational Capability

Since most of the O&G applications are distant from existing grids or no stablegrid is available, it is necessary to optimize the package for island operation.Once there is a demand change on power from local grid, the gas turbine has toprovide the corresponding need instantaneously such that the local grid canmaintain its frequency. This is, besides the constant and reliable power supply avery typical requirement within the Oil and Gas environment.

The standard speed range allows operation between 47.5 Hz and 51.5 Hz. Theoperation below or above these boundaries is limited to 20s maximum time and30 min accumulated operation time in the upper frequency range from 51.5 –52Hz and in the lower frequency range from 47Hz to 47.5Hz.

2.2.1.1. Start up time

A warm start up time in less than 20 minutes to base load can be fulfilled with thestandard load gradient of 11MW/min or 15 MW/min.

A Starting Frequency Converter is used to assist the start-up and operates thegenerator in synchronous start-up as a synchronous motor. When selecting theconverter, the required generator together with its excitation system is alignedwith the applicable Starting Frequency Converter. During start-up with the setpoint for the static excitation equipment of the generator is defined by the Starting

Frequency Converter. During normal operation the generator can be used ashelper to drive the compressor as well as supply electricity to the grid, in case ofgrid sustaining for example.

If a start-up time of maximal 10 minutes from turning mode to full load operationis demanded, than this requirement can be fulfilled for temperatures above -15°C. For very low temperatures a rotor preheating might become necessary andcan be implemented for cold ambient projects, as an option.

The start-up time below 10 minutes can be reached with the higher loadgradients of 30MW/min. For this scenario 9:46 min from turning mode (120rpm)

to base load operation are feasible within the ambient temperature range from -15°C to 40°C:


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2.2.3. Service Concept

The most probable service concept is based on replacement of key componentsusing the Roll-Out/Roll-In concept to keep outage times as short as possible.

Minor inspection must be executed every 16 kEOH (Equivalent OperatingHours). During each minor inspection, the combustion chambers are exchangedcompletely. Inspection of the turbine/compressor is performed according to arespective checklist.A Major Overhaul after 48 kEOH covers the key components of the gas turbineas, the complete rotor with inner casing, turbine guide vane assembly,compressor and combustion system. These components will be replaced onsiteand refurbished later on.

3. Cold Ambient

3.1. Market and requirements

One of the most critical issues for the operation of a gas turbine under coldambient conditions of course is the behavior of the materials that are in touchwith low temperatures. The degree of mechanical strengths referred to thetemperature change declines significantly faster in the cold ambient rangecompared to hot temperatures. As a result the embrittlement increases and the

risk of damages, caused by fatigue of the material, is immanent. Improvedmaterials or heating measures are covering these risks.The increased mass flow due to colder ambient conditions has to be consideredas well. This effect actually is positive with respect to power output. However thewhole configuration has to be able to cover an increased power output as well asoccurring effects like vibrations, stresses and axial thrust.

A significant part of the gas turbines provided by OJSC Power Machines andassembled by ООО Interturbo has been supplied to regions with extremely subzeroambient air temperatures in winter periods. For example, Novy Urengoi (up to -60ºС), Novo-Bogoslovsk (up to -50ºС), Perm (up to -50ºС), Izhevsk (up to -50ºС),

Vladimir (up to -45ºС), Kirovo-Chepetsk (up to -45ºС), Chelyabinsk (up to -48ºС)and others.Due to this reason many GTE-160 customers submit increased requirements toensure gas turbine reliable operation at ambient air temperatures below -15ºС.


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3.2. SGT5-2000E Standard Capabilities

The most recent version of the SGT5-2000E provides in simple cycle operation apower output of 170 MW with an efficiency of 35.3.Typical 2x1 Combined Cycle operation is capable for more than 500MW.Main lever of the power and efficiency improvements in comparison to previousversions is the introduction of the Siemens-Innovative-3-Dimensional TurbineBlades & Vanes (Si3D). The Si3D technology supports an optimized airfoildesign and a significant reduction of parasitic losses.Various SGT5-2000E gas turbines are in operation after implementing Si3Dblades and vanes for turbine stages 1 & 2 (e.g. 2x in Argentina, 4x Belgium,3xUnited Arab Emirates,2x United Kingdom). The first power plant that becameequipped with this technology for even stage 3 and 4 was Townsville (Australia)in 2009.

The Hydraulic Clearance Optimization is a further feature that improves thepower output by more than 1 MW. It enables the engine to reduce the clearancesduring the operation by hydraulic rotor shift, using pistons behind the axialcompressor bearing. The HCO was introduced in 2009 in Marib (Yemen) and hasproven more than 60000 EOH (Equivalent Operating Hours) worldwide.

3.3. Power Limit Increase of the SGT5-2000E

The SGT5-2000E is currently limited at a maximum power output of 170 MW.The main goal of the power limit increase (PLI) program is to further extend thislimit.

Figure 5 Influence of the power limit increase on the power output

P o w e r

O u t p u t

P before PLI

P after PLI

Compressor Inlet Temperature


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The benefit in power output for cold ambient temperatures is also shown in thefigure above. Assuming the measurements are successful, the extra power dueto the PLI is remarkable

The additional power results in a higher stage load for each stage in the turbine.Apart from minor validation efforts for other components the most criticalcomponents to be regarded if the power limit is increased are the last turbineblade rows. To evaluate these essential components measurements have to becarried out to analyze the frequency behavior under higher loads.

For the Power Limit Increase blade vibration measurements of the Turbineblades have to be carried out. As strain gauge measurements pose thedisadvantage that the measurements can only be successful in the first weeksafter commissioning, non intrusive NSMS (Non Intrusive Stress Measurement)

measurements were chosen as the best option for the flexible validation atadequate ambient conditions. Therefore the turbine blades rows have to beprepared for instrumentation. In each stage several probes have to be placedand therefore it was checked, if probe positions under the gas turbine areaccessible for the instrumentation and collision has to be avoided. The probeswere placed in accessible positions as shown in the figure below.

Figure 6 SGT5-2000E with NSMS probes

The probes can be placed when cold weather conditions occur and therewithhigh power output is guaranteed. After the measurement the probes can beremoved and no further exchange of casing components or rotor disks isnecessary. The optical sensors can be easily replaced if a defect is detected.After a successful validation and evaluation of the data a higher load for theaffected turbine blade rows can be released and therewith the higher power limitcan be confirmed.


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3.4. SGT5-2000E Optimizations for Cold Ambient temperatures down to -40°C

The target of the cold ambient program for the SGT5-2000E was to extend theoperation limit from -15°C to down to -40°C. Within this program all componentswere regarded and critical components were identified, such as the coldcompressor and casing parts of the engine. Moreover all operation conditionswere analyzed and the influence of the very cold ambient conditions on thecombustion regulation, rotor clearances and the secondary air system.

As an example, a whole core engine thermal analysis was conducted to ensurethat the expected temperature differences will cause no material stresses beyonda certain point. The figure below shows the temperature distribution in thecompressor vane carrier as a result of the 2 dimensional analyses.

Figure 7 Temperature analysis of compressor vane carrier

As another example the clearance limits especially during the warm up phase ofthe engine were evaluated and the clearances tolerances were adaptedaccordingly in order to avoid damages of the rotating equipment.

Some key features are the modified compressor inlet casing (CIC) and thecompressor blade 3. A material change became necessary for thesecomponents, as they are exposed to the cold inlet air. Furthermore the boltmaterials for the CIS-supports and the CIC-struts were optimized in order to bearthe forces.


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The bolt material of the Compressor Inlet Guide Vans (IGV) was revised andbeyond this material change the preset value for the adjusting force wasincreased by 40% as a more powerful IGV actuator is used.

The hardware changes go along with necessary validation efforts. Apart from allcalculations that were performed the final release of the SGT5-2000E for -40°C isassociated to validation measurements.

The measurements described in the following may give an overview of some ofthe validation procedures which are illustrated in Figure 8.

Before the measurements can begin, a tuning of the combustors has to takeplace during. The combustion process has to be evaluated with respect toignition behavior, fuel gas mass flow, resulting resonance and humming

frequency and last but not least the emission limits that have to be kept.

Figure 8 Cold ambient validation efforts for the SGT5-2000E

The key measurements after or during commissioning are the non contactcompressor blade vibration measurements for Compressor Blades and the nonintrusive NSMS measurement with the cold temperature resistant blade material.

Additionally the temperature and pressure for the air extractions, the cooling airtemperatures in Turbine Vanes, the pressure at the shaft sealing of the turbinebearing and the adjustment forces of the IGV have to be measured. After the first2000 EOH an inspection of the combustion chamber has to be considered.

After this validation program of the SG5-2000E is accomplished, its reliableoperation can be insured also under very cold conditions down to -40 °C.

Non contact blade vibration (BSSM)

Clearences at the flame tube

ceramic tile column

Adjustment forces of IGV

Cooling air temperatures andpressures

Pressures and temperatures at Compressor

Air Extractions

- Burner tuning during commissioning

- Combustion Chamber inspection after

commissioning and after 2.000 EOH

Pressure at shaft seal of turbine bearing

Commissioning/ Inspection

Validation Measurement


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3.5. SGT5-2000E Optimizations for Cold Ambient Temperatures below -40°C

One possible alternative to operate a gas turbine below -40°C based on themeasures mentioned above is the use of an air pre-heater system.These kinds of systems bear the necessity of heating large air masses of cyclingair in the air intake system, resulting in additional constant pressure losses on airheater in the filter house. This causes power losses and a decrease in combinedcycle plant efficiency.An alternative approach to the use of an air pre heater system is the furtherdevelopment of components, impacted by very cold temperatures.Further material substitutions especially for the compressor stages 1 - 4 and therespective rotor components have to be foreseen. The material for thecompressor bearing casing as well as for the inlet duct has to be improved as

well.Another measure is the front shaft heating which was already proven by anoperation down to an ambient temperature of -60°C.

4. Lookout

It is the distinct goal of the SGT5-2000 to serve an increasing amount of E-classmarket.However the SGT5-2000E has a tremendous potential to adapt furtherrequirements. Based on the maturity developed over the years and the world

class reliability and availability the design is open for a broad variety ofapplications beyond the power generation market.

5. Takeaways

The SGT2000E is a well proven gas turbine that proves its outstandingcapabilities with respect to availability, reliability, safety and operational flexibilityincluding start up behavior.These advantages are appreciated not within the power generation market only,but even within the Oil and Gas business.

The standard SGT2000E package operates down to -15 °C ambienttemperature.The operation down to -40 °C ambient temperature ca n be achieved as well,considering some dedicated adaptations as variations of materials for parts of theengine that are exposed to or impacted by the very cold intake air.For ambient temperatures below -40 °C air-pre heati ng or further materialsubstitutions have to be taken into account.The fleet of Siemens and his partners is able to gain experience from the gasturbine operation even down to -60 °C

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