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