www.siemens.com/energy
Powerful Products for the
Enhanced Flexibility of Gas Turbines
POWER-GEN Europe 2012,
Cologne, Germany
June 12–14, 2012
Authors:
Petra Michalke
Siemens AG
Energy Sector – Service Division
Thomas Schmuck
Siemens AG
Energy Sector – Service Division
Answers for energy.
Content
Abstract 3
Introduction 4
Enhanced flexibility for E-class gas turbines
5
Power Limit Increase 6
Wet Compression 7
Enhanced flexibility for F-class gas turbines 8
Advanced Stability Margin Controller
9
Advanced Compressor Mass Flow Increase 9
Turn Down 10
Turn Up 11
Wet Compression 12
Operational Flexibility Upgrade 12
Conclusion 13
References 13
Permission for use 13
Disclaimer 13
Copyright © Siemens AG 2012. All rights reserved.
2
Abstract
With a steadily growing share of renewable sources of
power generation and the ongoing development of competitive electricity and gas markets, the need is emerging
for additional flexibility in our advanced gas turbines.
The Advanced Compressor Mass Flow Increase and
Advanced Stability Margin Controller upgrades provide
our customers with the opportunity of additional flexible
power and an economical alternative to additional generation equipment.
The Advanced Compressor Mass Flow Increase upgrade
is part of the SGT5-4000F (V94.3A) new apparatus design
based on the proven SGT5-8000H design. The new 3D
compressor blade and vane profile is highly efficient,
resulting in a compressor mass flow increase and consequently in a power increase of up to 10 MW for the gas
turbine and 14 MW in combined cycle (1x1) operation.
The Advanced Compressor Mass Flow Increase upgrade
is retrofittable in the SGT5-4000F (V94.3A) service fleet.
The Advanced Stability Margin Controller continuously
monitors combustor behavior. The resulting feedback
enables automatic engine tuning and automatic engine
protection. In addition, the operator is informed about
potential issues with the combustion process. For natural
gas operation, the pilot gas volume and the turbine outlet
temperature are modulated by an automated control logic
to prevent the engine from high combustion chamber acceleration events. This supports engine operation with an
optimal power output at the lowest combustion dynamics.
Fast de-loading, gas turbine trips, and subsequent combustion-chamber inspections can be avoided by increased
combustion stability during part and base load operation.
By implementing the Advanced Compressor Mass Flow
increase and/or the Advanced Stability Margin Controller
upgrades, gas turbines can remain highly reliable and
competitive in the continuously growing F-class market.
3
Introduction
Gas turbine design and manufacturing technologies have
advanced significantly in the years since the first gas turbine VM1 was designed in 1956. More than 14 different
gas turbine types have been developed by Siemens since
then, reflecting the evolution of the electricity market,
changing environmental requirements including stewardship of available fuel resources, and the globalization of
the energy market.
The need for peak load and reserve capacity has been
continuously increasing in recent years. With a growing
quantity of regenerative energy generation (wind, solar)
being added to power systems worldwide, the requirement for reserve capacity that can be provided on demand
is also increasing. In Germany, for example, installed wind
generation capacity accounts for more than 26 GW
installed capacity, and significant additional generation
is being added through new offshore wind parks. The
proportion of the actual energy contribution from wind
generation in Germany is typically between five and
ten percent of annual energy generation, with generation
duration of approximately 18 percent on an annual hourly
basis. Clearly, reserve peaking capacity needs to be available on short notice when needed by the power system
to support renewable generation. As new projects usually
require protracted development periods due to long lead
times for site permitting and construction, an appropriate
alternative is to increase the capacity of power plants
already in existence. [1]
New design and manufacturing technologies – including
advances in design and modeling technologies and
the refinement of design criteria as well as advances in
material, cooling, and coating technologies – have also
been used to develop upgrades and component enhancements for the existing fleet. As the original equipment
manufacturer (OEM), Siemens has a huge advantage, and
continuously introduces technical enhancements within
its new unit and service business. The main market drivers
for gas turbine modernization within the service business
are the following:
■■ Power output increase
■■ Efficiency improvement
■■ Operational flexibility
■■ Reduction of maintenance efforts
■■ Emission reduction
■■ Improvement of reliability and availability
Selected products and technical solutions that enhance
the operational flexibility of V-frame gas turbines will be
explained in the following sections. These products will
improve grid or peak load capacity and part load operation
capacity and will expand existing maintenance concepts.
SGT6-8000H
2011
Technology
SGT5-8000H
2007
SGT5-3000E (V94.2A)
2000
SGTx-4000F (Vx4.3A)
1996
V84.3
V64.3 1994
1990
V94.3
1995
SGT6-2000E (V84.2)
1989
V94.1
1980
VM43
V93.0
1972
VM5
1960
SGT5-1000F (V64.3A)
1997
V82.0
SGT5-2000E (V94.2)
1981
V94.0
1974
VM80
1961
VM1
1956
1960
1965
1970
1975
1980
1985
Years
Fig. 1: Development path of V-frame gas turbines
4
1990
1995
2000
2005
2010
2015
Enhanced flexibility for E-class gas turbines
The SGT5-2000E (V94.2) is an extremely well-proven,
robust engine for the 50 Hz market and is used for simple
or combined cycle processes with or without combined
heat and power production in all load ranges, especially
in peak-load operation. The SGT5-2000E (V94.2) was
introduced in the early 1980s and was installed almost
300 times with its 60 Hz equivalent, the SGT6-2000E
(V84.2). Together this fleet has accumulated more than
20,000,000 equivalent operating hours (EOH). Several
modernization and upgrade solutions have been developed over the past 30 years reflecting various market
needs, for example, the changing requirements for
reserve capacity and flexibility.
Siemens’ most powerful modernization products for
enhancing the E-class gas turbine’s flexibility are the
Wet Compression upgrade and the Siemens innovative
3D-optimized (Si3D) turbine efficiency upgrade. With the
introduction of the Power Limit Increase to the SGT5-2000E
(V94.2), the remarkable advantages of the optimized turbine blades and vanes are used to achieve an even greater
increase in capacity.
2013
Siemens innovative 3D
optimized blades and vanes 1+2
[178+ MW; 36+ %**]
2008
[173 MW; 35,8 %**]
Efficiency
Compressor Mass Flow Increase
2001
41MAC
Firing Temperature Increase
HR3 Burner
2006
2003
1989
33MAC
Turbine Section Upgrade
1986
Wet Compression
203 Units in Commercial Operation*
Total EOH
Lead Unit EOH
> 14,800,000
>
266,000
Siemens innovative 3D optimized
blades and vanes 3+4
1981
Ongoing Development
Power Limit Increase (PLI)
[118 MW; 32,4 %]
Power Output
Additional Modernization & Upgrades
■■ Advanced Compressor Coating
■■ EVAP Cooler
■■ Fuel Gas Preheating
■■ Fuel Conversion
* As of March 2012
** Expected values only, site specific values may vary
Fig. 2: Customer-driven service product development SGT5-2000E (V94.2)
5
Power Limit Increase
Our latest development, specially designed for combined
heat plants (CHP) as well as for high power applications
like Wet Compression, is the Power Limit Increase (PLI),
which is based on the Siemens innovative 3D-optimized
(Si3D) turbine efficiency upgrade.
Gas turbine power output [MW]
With the latest Siemens innovative 3D-optimized turbine
blade and vane technology for the mature SGT5-2000E
(V94.2) frame, and based on the successful validation test
results in the winter of 2012, Siemens is currently preparing
the fleet release to expand the current power limit from
173 MW to 185 MW for all SGT5-2000E (V94.2) units
equipped with Siemens innovative 3D-optimized turbine
stages one to four. However, the unit-specific scope may
differ and is subject to a site-specific evaluation. This not
only means more power over the entire temperature
range, it also means additional output in the temperature
range below the current power limit, which was not accessible with gas turbine units of older design phases.
In addition, CHPs are operated primarily in northern countries where the demand for electricity meets an effective
way of producing district heating for households or industry.
District heating output at low ambient temperatures is
limited by the current power limit of the rear stages gas
turbine blades. With falling ambient temperatures, power
plants with service-exposed SGT5-2000E (V94.2) units are
affected in such a way that the closing inlet guide vanes
that limit the gas turbine’s power also throttle the district
heating output. This forces the power plant operator to
provide the extra heat energy required from other resources,
which usually operate less efficiently than the CHP. [2]
Compared with the reference case of a SGT5-2000E
(V94.2) from an older design stage, an increase of up to
four percent of exhaust gas energy can be utilized over a
wider ambient temperature range. This huge performance
increase helps strengthen power plant operators’ market
position.
185 MW
Additional benefit
of power limit
increase
173 MW
V94.2 with Siemens
innovative threedimensional optimized stages
1-4 and PLI at 1065°C*
V94.2 with Siemens
innovative three­
dimensional optimized
stages 1-4 and PLI at
1080°C*
V94.2 with CMF+,
­Siemens innovative
three-dimensional
­optimized stages 1-4
and PLI at 1080°C*
Compressor inlet temperature [°C]
Fig. 3: Customer-driven service product development SGT5-2000E (V94.2)
6
Reference V94.2
at 1060°C*
*TT1iso
Wet Compression
The Wet Compression upgrade is a reliable and proven
method of injecting water into the gas turbine inlet. Wet
Compression is perfectly suited for upgrading peak load gas
turbines. Providing peak power enables electricity producers
to react to increased grid power demand, for example, during summer peaks or grid fluctuations driven by renewable
energy sources, and increases customer revenues at high
peak load electricity prices. Wet Compression is designed
to increase power output up to 18 MW by injecting water
into the compressor inlet, which inter-cools the compressor,
reduces the compressor inlet temperature, and increases
mass flow throughout the gas turbine.
Wet Compression can be used for various purposes: the
most common and commercially attractive ones are:
■■ Seasonal operation (summer peak operation)
■■ Reserve power and occasional peaking
■■ Grid support
■■ Base load increase for simple cycle gas turbines
The seasonal operation of Wet Compression to compensate
for capacity losses during high ambient temperature conditions is possible in both dry and humid areas. Moreover,
a combination with an evaporative cooler or chiller is
possible as long as the compressor inlet temperature stays
above 10° Celsius. Implementing the Wet Compression
upgrade to increase the marketable power reserve and
for occasional peaking is ideal, because the impact on
the normal operation of the gas turbine is very minimal.
Wet Compression was developed in 1995 and redesigned
for the SGT5/6-2000E (V84.2 / V94.2) in 2003. More than
45 Wet Compression systems have been installed and
operated on Siemens E-class gas turbines since that year.
Power output at 30 °C ambient temperature related to the relative humidity
Delta power output (to Base Load, R.H. 10 %) [%]
20
Power output
18
with Wet Compr
ession (2 %-MVI
)
16
14
12
10
Pow
8
er ou
tput
with
6
Evap
orati
ve co
oler
(85 %
4
Eff.)
2
Base load power, dry
0
10
20
30
40
50
60
70
80
90
100
Relative humidity [%]
Fig. 4: Comparison of Wet Compression power output with an Evaporative Cooler at a variation of relative humidity
7
Enhanced flexibility for F-class gas turbines
The proven SGT5-4000F (V94.3A) is characterized by high
performance, low power generating costs, and long intervals between major inspections as well as an easy-to-service
design. Since 1996 more than 200 units have been
installed worldwide. Its 60 Hz equivalent SGT6-4000F
(V84.3A) was introduced in 1997 and has been sold more
than 50 times since then. Together this fleet has accumulated more than 10,000,000 EOH. The SGT5-4000F
(V94.3A) is based on the SGT5-2000E (V94.2) and on
proven standard design concepts. With optimized flow,
combustion, and cooling systems as well as new materials,
a gas turbine efficiency of nearly 40 percent ensures
a strong position in a competitive market.
Market requirements have been trending toward fast startup times, higher load gradients, and peak load capacity.
Research predicts the development of market demand in
the direction of even higher flexibility required of gas turbine operation modes. Our most powerful modernization
and upgrade products that meet the challenges of the
changing power generation market and enhance the
F-class gas turbine flexibility are the following:
■■ Advanced Stability Margin Controller (aSMC)
■■ Advanced Compressor Mass Flow Increase (CMF++)
■■ Turn Down
■■ Turn Up
■■ Wet Compression
■■ Operational Flexibility Upgrade (OFU)
2011
■■ Advanced Compressor Mass Flow Increase
[292 MW; 39.8 % 4)]
■■ Operational Flexibility Upgrade OFU
■■ Thermal Performance Upgrade
■■ Improved Hot Gas Parts
2010
SP6
2008
■■ Burner Upgrade (Low-NOx -> Premix-Pilot)
■■ Cooling Air Reduced Combustion Chamber
2005
Efficiency
■■ Burner Upgrade (Reduced Swirl)
■■ Fuel Gas Preheating
SP4
2004
■■ Compressor Mass Flow Increase
■■ Turndown
■■ Hydraulic Clearance Optimization
2003
19973)
■■ HR3 Burner
■■ Firing Temperature Increase
■■ 15 Stage Compressor
Ongoing Development
208 Units in Commercial Operation 1)
Total EOH
> 7,734,000
Lead Unit EHO > 119,000
2)
1996
[240 MW; 37.0 %]
■■ Further Firing Temperature Increase
■■ Grid and Peak Load Products
Power Output
Additional Modernization & Upgrades
■■ Advanced Compressor Coating
■■ Advanced Compressor
■■ EVAP Cooler
Cleaning System
■■ Advanced Stability Margin Controler
■■ Foreign Object Detection System
1)
3)
2)
As of March 2012
17-stage Compressor
4)
Since 1998: 15-stage compressor
Expected values only, site specific values may vary
Fig. 5: Customer-driven service product development SGT5-4000F (V94.3A)
8
■■ Wet Compression
■■ Fuel Conversion
Advanced Stability Margin Controller
The Advanced Stability Margin Controller increases
combustion stability during part and base load operation,
allowing more flexible operating conditions in part load
and a fast reaction to grid code fluctuations. The combustion
dynamic monitoring system continuously monitors combustor dynamic pressure fluctuations to provide feedback
for automatic engine tuning, automatic engine protection,
and to alert the operator to potential issues with the combustion process.
The combustion tuning potential by pilot-gas variation
at low load is limited due to upcoming combustion instabilities and cold or hot spot problematic. An increased
pilot gas mass flow reduces the cold spot problem but
increases combustion instability.
[Hz]
100
200
80
60
40
20
HuFlg_EnvSPEC
[mbar]
A decreased pilot gas mass flow reduces combustion
instability but increases the cold spot problem. Therefore
there is only a small range available for pilot gas tuning.
Depending on combustion stability, the pilot gas mass
flow or the turbine outlet temperature are modulated
to achieve a stable combustion. The Advanced Stability
Margin Controller provides closed-loop control of the
combustion acoustic and the simultaneous evaluation
of control parameters, resulting in a real-time adjustment
to changing gas quality, ambient conditions, and power
output. The Advanced Stability Margin Controller is based
on extensive knowledge and experience in gas turbine
combustion acoustics. Siemens Energy has extensive
experiences with more than three million accumulated
EOH worldwide.
150
100
50
0
14:10:00
14:15:00
14:20:00
14:25:00
Fig. 6: Combustion acoustics under active Advanced Stability Margin Controller during operation
Advanced Compressor Mass Flow Increase
This evolutionary component upgrade is based on the
well-proven Compressor Mass Flow Increase (CMF+)
introduced in 2003. The Advanced Compressor Mass Flow
Increase (CMF++) enhances the gas turbine’s power output up to 10 MW, and even up to 14 MW in combined cycle
operation (1x1). The established Compressor Mass Flow
Increase upgrade is the state-of-the-art in the new apparatus business for the F-class gas turbines and has accumulated more than 1,800,000 EOH since its first introduction
in 2003. The Advanced Compressor Mass Flow Increase is
its subsequent development and includes an aerodynamic
redesign of the first six compressor stages.
It realizes the latest advances: for example, a scoop design
of compressor row one. The improvements are based on
the SGT5-8000H compressor hardware design. The huge
performance increase is realized with no material changes,
no changes in flow paths, and with no impact on the EOH
accumulation.
Fig. 7: Gas turbine rotor with advanced compressor blades
9
Turn Down
A growing number of operators are requesting wider
ranges for part load operation, with the gas turbines still
achieving their emission requirements. With respect to
combined cycle power plants, this is constrained by the
need to keep the turbine outlet temperature at the high
base load level, allowing the steam turbine to be operated
at a high efficiency level as possible. The implementation
of the Turn Down upgrade is designed to answer the operator’s demand for lower gas turbine part load operation at
high combined cycle power plant efficiency levels. After
implementing a new linearization unit for the inlet guide
vane and a new positioning sensor, the closed position for
the inlet guide vane is adjusted to a new set point, which
results in an increased power range with low emissions
and constant turbine outlet temperatures. The actual
minimum part load depends on site-specific conditions
and the desired carbon-monoxide emission level. The set
point for the minimum part load is usually lower than
40 percent base load.
The Turn Down upgrade is the state-of-the-art for new
Siemens gas turbines for the F-class market and may
be combined with other modernizations. Since its first
application in 2003, more than 100 gas turbines have
been in commercial operation worldwide with more than
2,000,000 EOH.
Power
CO = constant
t gu
Inle
CO Limit
fully
ope
n
n ge
Cha
C
T
O
without Turn Down
Potential Benefit through
increased power range
with Turn Down
guid
Inlet
e van
e fu
ev
guid
Inlet
sed
lly clo
ane
fully
clo
with
ur
out T
ith
sed w
Use
Turn
Down
wn
n Do
D
Turn
ow n
OTC
Part Load OTC
(˜constant)
OTC = correct turbine outlet temperature
CO = carbon monoxide
Conceptual illustration only – actual results and experience may vary
Fig. 8: A higher turbine outlet temperature at part load can lead to increased combined cycle efficiency
10
id
ne
e va
Base Load OTC
Turn Up
The frequency response capability of combined cycle
power plants is generally activated by modulating the gas
turbine output. The steam turbine follows the gas turbine’s
changes with a physical delay in steam generation. The
Turn Up upgrade can be implemented in order to combine
the full availability of both the minimum primary and
secondary frequency reserve for a high continuous plant
output above 100 percent.
Due to the fact that Turn Up provides power above base
load, operation closer to the maximum efficiency point
can be realized while still preserving the entire primary
frequency response reserve. Consequently, the gas turbine operates at higher part load. Because the Turn Up
upgrade is designed for the optimization of primary
frequency response, fast load gradients are applied. The
average power output of the plant will increase; a minor
increase in average combined cycle efficiency can also
be expected.
Turn Up refers to opening the compressor inlet guide vane
beyond its standard design position, with an increase of
six degrees toward the open position. This leads to an
increased compressor mass flow resulting in an increased
gas turbine power output of up to six MW, while the
compressor efficiency remains nearly constant.
4 MW
ηGT
4 MW
Starting point with
standard configuration
Starting point with Turn Up
Turn Up
Base Load
Maximal Load
with Turn Up
96 %
97.5 %
100 %
~101.5 %
GT load
Fig. 9: Upgrade benefit: gas turbine operation closer to base load
11
Wet Compression
Operational
Flexibility Upgrade
Fig. 10: Wet Compression spider nozzle
Fig. 11: Schematic illustration of the Operational Flexibility Upgrade
As already described, the Wet Compression upgrade was
successfully introduced in the E-class gas turbines and
was redesigned for the F-class market to meet their
changing requirements regarding plant flexibility and
capability. The commissioning of the first application on
the advanced frame SGT5-4000F (V94.3A) was successfully accomplished in 2010. The system shows a similar
potential as on the SGT5-2000E (V94.2). The highest
delta gas turbine power output of about 16 percent has
been measured at a Wet Compression mass flow of about
10.2 kg/s. In addition, the gas turbine’s efficiency has
been increased by about two percent. The achievable
maximum power output of up to 30 MW with Wet
Compression is limited by a maximum water mass flow
(two percent of the compressor inlet mass flow). However,
not all sites can reach the full potential of Wet Compression due to site-specific limitations that include generator/
transformer limits, shaft limits, combustion instabilities,
and special limiting hardware configurations. [1]
The Operational Flexibility Upgrade (OFU) is an integration of proven products that optimize the individual power plant performance and increasing operational flexibility within a long-term service agreement. The Operational
Flexibility Upgrade combines proven technologies that
include improved blade and vane design and enhanced
combustion technology.
The Operational Flexibility Upgrade includes a turbine
performance upgrade that modifies key turbine components and hot gas parts, allowing for a significant firing
temperature increase. This modernization has been
designed to generate a power increase, an improvement
in heat rate, and additional exhaust energy. These
results are achieved through the application of new coatings on the turbine blades and vanes and a reduction in
cooling air in the hot gas path. In addition to the performance increase, the Operational Flexibility Upgrade allows for a maintenance interval extension to 33MAC.
This results in increased availability of the entire plant,
because the major outage is only performed every
33,000 EOH.
The following benefits can be achieved:
■■ Up to 13 MW gas turbine power output increase
in simple cycle operation
■■ Up to 21 MW combined cycle power output
improvement (1x1)
■■ Up to 0.4 percentage points combined cycle
efficiency improvement
■■ Potential reduction of NOX emission
down to 15 ppm
The Operational Flexibility Upgrade optimizes upgrade
combinations and provides the best unit-specific balance
of plant solutions, with the maximum possible performance increase and enhanced maintenance intervals
as part of a long-term program contract extension. The
Operational Flexibility Upgrade is the ticket to a flexible
operating domain that extends the original equipment
manufacturer coverage beyond 100,000 EOH and can be
implemented at any outage during the long-term service
agreement program. The Operational Flexibility Upgrade
will typically be implemented at the 100,000 EOH
outage.
12
Conclusion
Disclaimer
Recent improvements in turbine technology have produced major benefits, including increased flexibility and
improved reliability and availability. All of these benefits
make a gas turbine modernization project attractive and
highly beneficial for aging power plants. In addition,
short lead times for the realization of these modernizations and upgrades – when compared with new installation projects – enable a response to near-term capacity
needs.
These documents contain 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 these
documents are the property of Siemens AG, its affiliates
or their respective owners.
The upgrade solutions described above – the Power Limit
Increase, Wet Compression, and Operation Flexibility
Upgrade packages, among others – represent only a
small part of the solutions provided for the Siemens gas
turbine fleet today, and reflect the market’s demand for
enhanced capability and flexibility. Many more solutions
are available, and they can be combined to address the
customer’s need for not only improved flexibility but also
high reliability and availability with reasonable maintenance costs and reduced emissions.
Each upgrade step is verified with various test methods
to ensure reliable engine operation. The proven product
development process and the integrated validation concepts demonstrate an extensive quality assurance model
for our customers. As part of this continuous research
and development process, Siemens is committed to
delivering excellent solutions that are highly beneficial
for the power generation industry.
References
[1] Beiler, J. D. “High Efficient Peak Power on Demand.”
Publication, Siemens AG, 2011.
[2] Sorgenfrey, Chr. “Beneficial lifetime extension
of SGT5-2000E gas turbines through modernization.”
Publication, Siemens AG, 2011.
Permission for use
The content of this paper is copyrighted by Siemens and
is licensed to PennWell for publication and distribution
only. Any inquiries regarding permission to use the content of this paper, in whole or in part, for any purpose
must be addressed to Siemens directly.
13
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The required technical options should therefore
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