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3rd SEC-Siemens
Technology Forum
Latest Developments of Siemens Heavy Duty Gas Turbines for the
Saudi Arabian Market
Adam Foust, 5000F Package Frame Manager
siemens.com/answers
Restricted © Siemens AG 2014. All rights reserved
Agenda
Page 2
Mar-14
slide
•
5000F Evolution & Statistics
3
•
Design Changes
4
•
Package Overview
5
•
Gas Turbine Overview
6
•
Testing & Verification
7
•
5000F(5ee) Power
9
•
5000F(5) in Saudi Arabia
11
•
Fuel Flexibility
12
•
Service
14
•
Air-cooled Generator
15
•
Summary
16
3rd SEC-Siemens Technology Forum
• 80 units in simple cycle
SGT6-5000F Evolution
Successful Heritage of the 5000F Platform
• 30 units in 1x1 cc
• 127 units in 2x1 cc
• 30 units in 3x1 cc
• 12 units in 4x1 cc
SGT6-5000F Evolution
SGT6-5000F Experience
• 279+ units in operation
net power
240
Compressor
(minor)
220
Turbine
(minor)
• 9.4+ million operating hours
• Reliability consistently >99%
as reported by our customers (230 units)
Compressor
F(4) fleet >99.6% reliability
Turbine
200
Compressor
GTs in
Operation
Compressor
180
Hours
(fleet leader)
160
SGT6-5000F Introduction
140
1993
1997
2001
2005
year of commercial operation
2009
2013
2015
501F
FC
FD
FD2
F(3)
F(4)
4
36
19
142
49
28
158k+ 109k+ 124k+ 96k+ 40k+ 23k+
• 34 F(5) units sold (24 units in KSA)
• 8 F(5ee) units sold (6 units in KSA)
• 12 F(3i) units sold configured for syngas (10 units in KSA)
Low Risk Evolutionary Design Approach with Proven Reliability
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3rd SEC-Siemens Technology Forum
SGT6-5000F(4) / F(5) / F(5ee)
Design Features
The F(4), F(5), and F(5ee) Have the Same Firing Temperature
Improved rear stage aerodynamics from F(5) to F(5ee)
• Stage 1 and Stage 2 validated in Service fleet (37K+ hours)
• Similar exhaust on 4000F
Single tie bolt rotor for F(4), F(5), F(5ee)
• 22K+ hours on lead 5000F unit
• Similar single tie bolt rotor on 4000F and 8000H
13-stage compressor for F(4), F(5), F(5ee)
• 22K+ hours on lead 5000F unit
Enlarged compressor inlet from F(4) to F(5)/F(5ee)
• Same compressor in commercial operation on 8000H
• Base load achieved on F(5) in commercial operation
Page 4
Mar-14
3rd SEC-Siemens Technology Forum
Restricted © Siemens AG 2014. All rights reserved
SGT6-PAC 5000F
5000F Package Overview
Rotor Air Cooler
• Constant cooling air temperature
• Fuel gas heating option
• Kettle boiler option
SGT6-5000F
• 232 MW @ +38.8% eff
• Retrofittable combustion and turbine parts
Inlet System
• Pulse filter
• Evap cooling
Turning Gear (120 rpm)
• Facilitates a ‘smooth’ start
• Uniform cool down
Air Cooled Generator
• Simplified plant interfaces
• TEWAC
• Easy access and maintenance
Starting System
• SFC (air cooled)
The SGT6-5000F Package is Well-Suited for the KSA Environment
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3rd SEC-Siemens Technology Forum
SGT6-5000F
Gas Turbine Design Features
The Most Powerful 60Hz F-Class Gas Turbine in the World
Lowest firing temperature in the market:
• Low NOx emissions
• Longer part life
• Conventionally cast turbine material
(no need for single crystal material)
Combustion
• Wide Wobbe operation
• Sub 9ppm emissions
High power output on hot days:
• More mass flow via opening IGVs
(no change in firing temperature)
Compressor
• 13 stages
Turbine
• 4-stages
• Conventionally cast parts
Rotor
• Constant rotor cooling air temperature
• Steel discs w/ Hirth serrations
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Mar-14
3rd SEC-Siemens Technology Forum
4-stage turbine:
• Reliable part life due to lower
aerodynamic loading when compared to a
3-stage turbine at the same power output
Constant rotor cooling air temperature:
• Constant temperature up to 55oC ambient
• Predictable rotor life regardless of
ambient temperature
SGT6-5000F Development
Testing and Verification Before Implementation
5000F(3)
5000F(4)
Commercial
operation in 2005
Commercial
operation in 2009
Test Date
2003
2005
5000F(5)
5000F(5ee)
Commercial operation
in 2014
Commercial operation
expected in 2014
2013/2014
2006
Off nominal testing…
• Compressor surge limits
• Transient operation
• Fuel transfers
• Load rejections
Page 7
Mar-14
Turbine Rear Stage Aerodynamics
and Optimized Diffuser Flow Path
3rd SEC-Siemens Technology Forum
SGT6-5000F(5ee) Berlin Testing Update
Mechanical Verification and Performance Testing have been
Successfully Completed in the Berlin Test Facility!

Performance (base load, part load)

Operations (start-up, off-speed, trip, restart, etc)

Combustion stability and emissions

Turbine row 4 blade flutter

Rotor dynamics
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3rd SEC-Siemens Technology Forum
SGT6-5000F(5ee) Power
The SGT6-5000F(5ee) has High Power Output on Hot Days
240 MW
Inlet chilling
230 MW
Evap Cooling
(10% rel. humidity)
220 MW
Evap Cooling
(30% rel. humidity)
210 MW
200 MW
Evap Cooling
(60% rel. humidity)
190 MW
F(5ee) Power
without TIAC
180 MW
0C
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Mar-14
10C
20C
30C
3rd SEC-Siemens Technology Forum
40C
50C
First SGT6-5000F(5) Achieves Base Load
And Exceeds Performance Guarantees
First Fire
240 MW
FSNL runs
232 MW Net Power
220 MW
Jan 16th, ‘14
200 MW
Day 2 & 3
Day 4
180 MW
160 MW
140 MW
5000F(5) gas turbine
shipping to the Kingdom
120 MW
100 MW
First 5000F(5) gas turbine achieves base load at the
Ras al Khair site in the Kingdom of Saudi Arabia
80 MW
60 MW
40 MW
20 MW
0 MW
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Mar-14
3rd SEC-Siemens Technology Forum
Combustion
Fuel Flexible, Reliable, Low Emissions
Siemens is committed to the Energy Demands and Fuel
Flexibility Policies of the Kingdom of Saudi Arabia
Syngas
ASL
Condensate
Low Btu gas
(~40% inerts)
AXL
Commercial Operation
Tested
Testing planned
(April / May ’14)
Testing planned
(April / May ’14)
Testing tentatively planned
(early 2015)
30 SGT6-5000F units in KSA
w/ ULN Nozzles
Page 11
Mar-14
10 SGT6-5000F units in KSA
w/ DF42 Nozzles
3rd SEC-Siemens Technology Forum
Additional fuel capabilities:
• Bio-diesel
• Natural gas + H2
• High Wobbe Index fuels
Oil Status  Siemens sets a new benchmark for
emissions “25ppm NOx”
“Siemens SGT6-5000F sets a new benchmark in the industry
demonstrating 25ppm NOx emissions on fuel oil.”
Competition
NOx @ 15% O2 (ppmvd)
45
40
35
30
25
Siemens ULN
20
15
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
Water to Fuel Ratio
Siemens is the leader in fuel oil technology and has set the benchmark in the industry.
Page 12
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3rd SEC-Siemens Technology Forum
KSA Liquid Fuels
• Viscosity, flashpoint, vapor pressure and
boiling temperature properties different
than Diesel Oil.
• ASL, AXL, and Condensate evaporate at
lower temperatures compared to standard
Diesel Oil and this creates potential
combustion flashback risk.
Distillation Curves
Coking Risk
Combustion
Flashback Risk
Naphtha
Parameter
Distillate#2 ASL Typical
60oC
-25oC
7.0 kPa
52.7 kPa
Kin. Viscosity (40oC)
3.0 mm2/s
1.25 mm2/s
Calorific value, lower
43,000 J/g
42,494 J/g
Density (15oC)
840 kg/m3
780.8 kg/m3
Flashpoint
Vapor pressure (40oC)
KSA liquid fuels evaporate
faster than diesel oil which
causes flashback
Combustion flashback identified as potential risk with light oils (ASL, AXL, Condensate)
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3rd SEC-Siemens Technology Forum
Arabian Super Light crude oil
Testing Completed to Guarantee ASL Performance
Rig testing confirmed the 5000F is capable with ASL fuel
1100
Distillation Curves
Boiling Temperature (°F)
1000
900
Diesel Oil
800
Arabian Super Light Crude (ASL)
700
ASL composition differs from
typical diesel oil thus rig testing
was completed to qualify the fuel
Khuff Condensate
600
ASL is 100% vaporized @ ~1,050oF
Diesel oil is 100% vaporized @ ~700oF
500
400
300
200
100
0
20
40
60
80
100
% Recovered
API Gravity
30o
40o
Diesel Oil
AXL
50o
53o
ASL Condensate
AmericanPetroleumInstitute Gravity = [141.5 / SpecificGravity ] – 131.5
Light crude oil has a low specific gravity (high API gravity)
due to the presence of a high proportion of light
hydrocarbon fractions and typically has a low wax content.
Page 14
Mar-14
3rd SEC-Siemens Technology Forum
Full Pressure and Full Firing ASL Rig
Testing Completed in July ’13.
Arabian Super Light crude oil
Logistics
Testing and Handling of ASL Confirmed that No Pre-treatment
of ASL was Necessary for Pumping or Combustion.
ASL was transported from KSA to Germany in 5
tank-tainers (~755 barrels) and stored at a fuel depot
until the start of testing
Testing facility (tanks and
forwarding system) was modified to
accommodate ASL fuel
Page 15
Mar-14
3rd SEC-Siemens Technology Forum
Arabian Super Light crude oil
Testing Combustion Operability
Testing established that combustion dynamics, flashback, and
emissions on ASL are similar to diesel oil.
No flashback at base load conditions
and 115 bara ASL supply pressure
NOx calibration
W/F ratio
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Mar-14
NOx emissions
3rd SEC-Siemens Technology Forum
Arabian Super Light crude oil
Combustion Operability During Loading
The same ULN combustion system can accommodate diesel
oil and ASL by varying the water / fuel ratio
1.20
Water / Fuel Ratio
1.00
0.80
ASL water / fuel ratio
0.60
0.40
Typical diesel oil water / fuel ratio
0.20
0.00
0%
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Mar-14
20%
40%
60%
Normalized Gas Turbine Load
3rd SEC-Siemens Technology Forum
80%
100%
Arabian Super Light crude oil
Auxiliary System
The only modifications in the auxiliary system are the oil pump (suitable
for ASL specific gravity) and the water injection system (higher capacity)
WATER INJECTION PUMP SKID
16X
Hyd
• ASL operating temperature should be
the same as diesel oil (5oC to 40oC)
Air
filter
16X
water
Water Injection
Pump Gear Box
• No ASL pretreatment is required (fuel
factor accounts for composition
difference to diesel oil)
16X
Hyd
Water injection pump
Multi-function
Valve
16X
16X
16X
16X
ASL Pump
Pilot
filters
Air
B
Drain
System
fuel oil
Hyd
16X
16X
Flow divider
FUEL OIL PUMP SKID
FOWI SKID
Page 18
Mar-14
A
3rd SEC-Siemens Technology Forum
Liquid Fuel Contaminant Limits
Contaminant limits are valid with project specific configuration,
performance, fuel factors, and service agreements.
Units
Suggested Limits1
Rabigh II
Diesel oil
Ash
ppm
3.0
3.0
0.01% wt
Na + K2
ppm
<2.1
2.1
<1.0
Lead
ppm
<1.0
<1.0
<1.0
Vanadium3
ppm
<0.5
0.5
<0.5
Wax4
%
3.0
0.0
N/A
Pour Point
oC
-30
-35
-23
Cold Filter Plug Point
oC
-5
-7
-15
Carbon Residue
% wt
<1.0
<1.0
<0.15
Calcium
ppm
10.0
10.0
10.0
Sulfur
% wt
0.2
0.1
0.2
1 If
the composition of the actual fuel supplied to the gas turbines exceeds these suggested composition limits, the auxiliary systems and gas
turbine operation may be impacted requiring modification, fuel treatment, or adjustment of the fuel factor.
2
If the suggested Na + K limits exceed 2.1 ppm, an oil washing system can be implemented to reduce levels or the fuel factor applied to
turbine parts can be adjusted based on the validation inspections planned for the lead unit.
3
If the suggested Vanadium limits exceed 0.5 ppm, inhibitors can be added to the fuel or the fuel factor applied to turbine parts can be
adjusted based on the validation inspections planned for the lead unit.
4
3.0% wax content is acceptable as long as the Cold Filter Plug Point (CFPP) and Pour Point temperature limits are not exceeded
Page 19
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3rd SEC-Siemens Technology Forum
Restricted © Siemens AG 2014. All rights reserved
Arabian Super Light crude oil
Test Results Summary
ASL testing has confirmed that reliable base load performance will
be guaranteed with the existing ULN combustion hardware:
• SGT6-5000F(5ee) design is capable with ASL fuel from start-up to base load.
• GT performance and emissions will be guaranteed on ASL fuel.
• The potential risk of combustion flashback was mitigated by varying the water / fuel ratio.
• Service Intervals will be guaranteed with an ASL fuel factor. A fuel factor of 3.0 is applied to
combustor parts only during ASL operation (fuel factor for turbine parts remains at 1.3).
Combustion hardware was instrumented
to measure flashback, dynamics, metal
temperatures, and emissions
Page 20
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3rd SEC-Siemens Technology Forum
Gas Turbine Service Intervals
5000F Hot Gas Path Inspection @ 22,000+ Hours
Lower Firing Temperature = Lower Risk in Service Operation
Vane 4
Combustor
Nozzles
Vane 3
Combustor
Basket
Vane 1
Blade 1
Vane 2
F(4) parts shown are
identical to F(5) and
similar to F(5ee)
Page 21
Mar-14
3rd SEC-Siemens Technology Forum
SGen6-1000A
Air Cooled Generator
• Air cooled configurations (OAC and
TEWAC) to meet the environmental
conditions in the region
• 12 OAC in the Kingdom
• Air cooled for simplified plant interfaces
• 30 year design life @ IEEE Class F
temperature rise
Page 22
Mar-14
3rd SEC-Siemens Technology Forum
Thank You from the Orlando, FL, USA Office!
Gas Turbine Manufacturing in the Kingdom of Saudi Arabia
Charlotte, North Carolina, USA
Gas Turbines
Dammam, Saudi Arabia
Generators
Steam Turbines
Page 23
Mar-14
3rd SEC-Siemens Technology Forum
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 forwardlooking 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
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projected. Siemens does not intend or assume any obligation to update or revise these forwardlooking 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.
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Mar-14
3rd SEC-Siemens Technology Forum
Restricted © Siemens AG 2014. All rights reserved
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