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 Page 3 Mar-14 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 Page 5 Mar-14 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 Page 6 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 Page 8 Mar-14 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 Page 9 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 Page 10 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 Mar-14 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) Page 13 Mar-14 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 Page 16 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% Page 17 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 Mar-14 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 Mar-14 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. 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