MGT Products & Maintenance
Continuous Improvement
Dr. V. Navrotsky, MGT Fleet Director
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Page 1
Outline
• Introduction
• Operating experience
• Performance enhancement
• Repair solutions
• Life extension program
• Maintenance improvement
• Summary
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Page 2
Siemens Product range
Steam Turbines, Gas Turbines & Compressors
Combined GT Products (MW)
Utility Turbines
1900
Utility application
1100
1200
700
300
250
200
180+
150
130+
100
85
65
50
10
9
3
0.45-5
Industrial application
Industrial application
Utility application
Combined ST Products (MW)
SST-9000
SST-8000
SST-6000
SST-5000
SST-4000
SST-3000
SST-1000
SST-900
SST-800
SST-700
SST-600
SST-500
SST-400
SST-300
SST-200
SST-100
SST-050
KK&K
Home Market
SGT5-8000H
SGT-4000F
SGT-6000G
SGT-3000F
SGT-5000F
SGT-2000E
SGT-3000E
SGT-1000F
SGT-800
SGT-700
SGT-600
SGT-500
SGT-400
SGT-300
SGT-200
SGT-100
340
265
253
190
187
157
121
68
47
30
25
17
13
8
7
5
Siemens turbocompressors
Single shaft
 STC-SH
 STC-SR



STC-SI
STC-SO
STC-SP



STC-STO
STC-SV
STC-SX
Integrally geared
 STC-GC
 STC-GV



STC-GO
STC-GT
STC-GTO

STC-GVT
 STC-SPCP

STC-ECO
Siemens offer a full power range of Steam Turbines,
Gas Turbines & Compressors for Industrial and O&G markets
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Page 3
Compressor for O&G solutions
Continued Product and Maintenance Improvement
Efficiency Enhancement
Product
Performance
Enhancement
Rotating
Equipment
Product &
Maintenance
Improvement
Power Output Enhancement
Emissions reduction
Life time extension
Repair & Refurbishment
Maintenance
Enhancement
Maintenance Intervals extension
Maintainability Improvements
Focus on Power plant Profitability and Competitiveness Improvement
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Page 4
Outline
• Introduction
• Operating experience
• Performance enhancement
• Repair solutions
• Life extension program
• Maintenance improvement
• Summary
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Page 5
MGT Operating Experience
SGT- 500
SGT- 600
SGT- 700
SGT- 800
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Page 6
MGT Operating Experience
SGT-500 first introduced (started) 1955.
DLE introduced 1994.
Total of units sold today is 178
Total in commercial operation 118
Total fleet operating hours > 9 million hours
- > 220 000 of those on DLE
 Fleet leaders
- > 230 000 hours





SGT-SGT500 500







SGT- 700
SGT-700 first introduced (started)
2004.
DLE standard.
Total of units sold today is 65
Total in commercial operation 53
Total fleet operating hours > 900 000 hours
Total number of starts > 7 000
Fleet leaders
- PG: > 65 000 hours
SGT- 700
- MD: > 66 000 hours
SGT-600 first introduced (started) 1986.
DLE introduced 1991.
Total of units sold today is 309
Total in commercial operation 190
Total fleet operating hours > 7 million hours
- > 5 million of those on DLE
 Fleet leaders:
- >160 000 hours





SGT- 600
SGT- 800
 SGT-800
first introduced (started) 1999.
 DLE standard.
 Total of units sold today is 229
 Total in commercial operation 120
 Total fleet operating hours > 2 500 000 h
 Fleet leaders
- PG: > 90 000 hours
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Page 7
SGT- 600
SGT- 800
SGT- 800 Operating Statistic
Systematic follow up, analysis & action
Down Time (Forced Outage Rate) Reduction
SGT-800 surpassed its Key Performance Indicator goals
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Page 8
SGT-800 Upgrade
47MW rating
Compressor blade 1
Modified Components:
 Compressor blade 1
 Turbine blade 1
 Turbine vane 1 and 2
Turbine cooling air supply modification:
 Swirl generator dimension
 Orifice dimension in extraction from
compressor stage #10
Turbine blade 1 and Turbine vane 1 and 2
2 MW
Heat Rate, MJ/kwh
Generator Output, MW
Comparison between 47 and 45 MW rating
Compressor Inlet Air Temperature, C
Limited modifications enable + 2 MW and + 0.5 % efficiency to support
Customer
competitiveness
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AB 2014. All rights
reserved.
Page 9
Outline
• Introduction
• Operating experience
• Performance enhancement
• Repair solutions
• Life extension program
• Maintenance improvement
• Summary
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Page 10
SGT- 700
Development history and operating experience
30
25
•
•
•
•
•
•
•
SGT-700 first introduced 2001
DLE standard
Total of units sold today is 65
53 units are in commercial operation
Total fleet operating hours ≈ 900 000 hours
Total number of starts > 7 000
Fleet leaders:
- PG: > 65 000 hours
- MD: > 66 000 hours
Extended TBO (20 000 h to 30 000 h)
Current fleet can be upgraded
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SGT-700 Upgrade
31.2 MW rating
The compressor turbine efficiency has been improved by:
 Reduced cooling air from areas which has been over cooled
 Introduction of TBC - reduced required cooling air
 Improved sealing – reduced leakage
Reduction of cooling air and leakages gives
more air to combust and more flow through
vane 1 which results in higher power and
efficiency.
+ 2,2 MW higher power to support higher Power production
+ 0,4 % higher efficiency to improve Power Plant profitability
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Page 12
SGT-800 Industrial gas turbine
Development and Status timeline
More than 225 units sold and 2.5 million EOH accumulated
Design, validation,
manufacturing
Ratings now sold in parallel
43.0 MW
1995 1996
1997
1998
1999
2000
45.0 MW
2001
2002
35 units sold
25 units sold
Fleet leader: > 100 000 EOH
2003
2004
2006
2007
50.5 MW
2008
114 units sold + 6 upgraded
Fleet leader: > 60 000 EOH
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47.5 MW
2009 2010
54 units sold
Fleet leader:
> 23 000 EOH
SGT-800 Industrial gas turbine
Enhanced performance to 50.5 MW
Compressor:
Improved blade profiles
Burner tuning and minor
combustor design adjustments
Vane #1:
Blade #1:
Reduced number of airfoils Improved cooling matrix
TBC also on airfoil
Reduced number of blades
Improved cooling design
Blade #3:
9% longer blade and modified
exhaust diffuser heat shield
Stator rings instead of segments
Vane #2:
TBC also on airfoil
New cooling inserts
Vane #3:
Integrated heat shield
Improved profile
Improved compressor airfoil profile resulting in about 1% higher mass flow and improved aerodynamics
Improved turbine stage #1 aerodynamics and more efficient cooling air layout
Improved turbine stage #3 with increased outlet area (reduced exit losses) and improved aerodynamics
Turbine Inlet Temperature (TIT) is not increased compared to the 47.5 MW rating
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Page 14
Example III: Measured NOx and CO (DLE)
SGT800-Emissions
100.0
2500
80.0
2000
PFR-SP %
70.0
60.0
1500
50.0
40.0
1000
30.0
20.0
CO (ppm@15%O2)
NOx (ppm@15%O2), PFR_SP (%)
90.0
NOx ppmvd@15
CO ppmvd@15
500
10.0
0.0
0.0
20.0
40.0
60.0
80.0
100.0
0
120.0
Load (%)
Impressive NOx and CO performance demonstrated
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Page 15
SGT-800 Industrial gas turbine
Enhanced compressor performance
Enhanced compressor
SGT-800 electrical power output and heat rate at ISO conditions
60000
• Hot Ambient Match option with
optimized stage matching for high
ambient temperatures
•
•
26% more power @ 50°C
5.8% reduction in Heat Rate @ 50°C
55000
11000
Power
50000
10500
45000
10000
40000
9500
Heat Rate
35000
9000
30000
8500
Normal Match
25000
8000
-10
-5
0
5
10
15
20
25
30
35
40
45
50
Ambient temperature, °C
Compressor stator stage #3 to #15 option:
Normal or Hot Ambient Matching
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Page 16
Hot Ambient Match
Heat rate, kJ/kWh
Generator power output, kW
• Optimized front stage geometry
• Enhanced airfoil profiles for all stages
• Rotor and casing design unchanged
gives retrofit ability
• Improved efficiency and stability
• Increased mass flow
11500
SGT-800 50.5 MW version
Hot Ambient Matching
Hot Match
Restagger Angle
stage#
deg
S3
S4
S5
S6
S7
S8
S9
S10
S11
S12
S13
S14
S15
-1.5
-2.5
-3.8
-3.5
-5
-4
-6
-3.8
-3.5
-3
-3
-3
-4
Hot Ambient Match angle
+ dir
Normal Match angle
dir
Optional stagger angles of stator #3 to #15 for Normal and Hot Ambient Matching respectively
All other engine parts are identical
Peak efficiency for the compressor moves 200 rpm in normalized speed (corresponds to 17 degC C)
Nominal VGV closing point moves from +33 degC C to +50 degC C
=> Higher power output at high ambient
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Page 17
SGT-800
Best in class combined-cycle performance
Combined Cycle
dual pressure, no reheat
Net Plant
Heat Rate
Net Plant
Heat Rate
Gas Turbine
Steam Turbine
Output (kW)
(Btu/kWh)
Efficiency
(kJ/kWh)
Power (kW)
Power (kW)
SCC-800 1x1
66 570
kW
6344 Btu
53,8%
6693 kJ
46 300 kW
21 000 kW
SCC-800 2x1
135 370
kW
6239 Btu
54,7%
6583 kJ
92 600 kW
44 200 kW
SCC-800 1x1
71 400
kW
6193 Btu
55,1%
6534 kJ
49 100 kW
23 100 kW
SCC-800 2x1
143 600
kW
6159 Btu
55,4%
6498 kJ
98 300 kW
46 800 kW
SGT-800 Evolution
ISO Base
Heat Rate
Efficiency
Press
54
Rating (kW)
(Btu/kWh)
Ratio
SGT-800
47 500
kW
9 057
Btu
37,7%
20,2
SGT-800
50 500
kW
8 916
Btu
38,3%
20,8
Power rating (MW)
Simple Cycle
52
50
48
46
44
42
“Stepwise evolution building on
experience and proven design solutions”
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40
1998
2000
2002
2004
2006
2008
Year of first engine start
2010
2012
2014
SGT-600 Upgrade
to support Customers’ demands & flexible operation
Flexible operation




cyclic operation mode
Start reliability
Fast start up
Flexible maintenance
Part Load operation:
 Emission improvement
 Efficiency improvement
 Accounting lower life consumption
when running on part load
.
Focus on further emission reduction, flexible operation & life extension
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Page 19
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)
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Page 20
Outline
• Introduction
• Operating experience
• Performance enhancement
• Repair solutions
• Life extension program
• Maintenance improvement
• Summary
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Page 21
Current repair status SGT-800
Repairs according to maintenance plan & on-condition
1st Blade
Combustion Chamber
Heat shields
Sealing edge repair
Sealing edge repair
Burners
Abradable rings
Ready
Under development
1st Vane
2nd Vane
SGT-800 repair as a part of Maintenance Program to reduce maintenance cost
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Current repair status SGT-700
Repairs according to maintenance plan & on-condition
Repairs according to maintenance plan & on condition
(for current standard components)
Turb blade #1
2nd Vane
Comp, recoat
abradable rings
1st Vane
Burner
Honeycomb seals
Sealing edge replacement
Ready
Under development
Combustion Chamber
SGT-700 repair as a part of Maintenance Program to reduce maintenance cost
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Current repair status SGT-600
Repairs according to maintenance plan & on-condition
Comp, recoat
abradable rings
Combustion Chamber
Honeycomb seals
Comp, blade &
vane recoating
Sealing edge replacement
Ready
Under development
1st Vane
Turb blade #1
2nd Vane
SGT-600 repair as a part of Maintenance Program to reduce maintenance cost
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Current repair status SGT-500
Repairs according to maintenance plan & on-condition
Flame head
Combustor
Fuel injectors
LP & HP comp recoating
Ready
Under development
Gas collector
Repair as a part of Maintenance Program to reduce maintenance cost
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Page 25
Outline
• Introduction
• Operating experience
• Performance enhancement
• Repair solutions
• Life extension program
• Maintenance improvement
• Summary
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Page 26
MGT Maintenance Concept





Maintenance plan optimized for cost and
availability
Long time between overhauls
(up to 30,000 EOH)
Flexible operation & maintenance
Components Cyclic life extension
Possibility to add 2nd maintenance cycle after
120,000 EOH by applying a RCIE (Rotor &
Casing Inspection & Evaluation) program
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Maintenance down time reduction
Extension of maintenance intervals -> 3 overhauls instead of 5
 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”
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% ©&Siemens
supports
customers
towards
flexible operation & maintenance
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Page 28
MGT RCIE
Rotor and Casing Inspection and Evaluation (RCIE)
RCIE - Major Activities




Unit specific non-destructive
tests to determine status of
major components
Outcome: Tailored scope of
repair / replacement
Level-C activities performed at
120,000 EOH, with necessary
extended scope + additional
Modernizations and Upgrades
Unit specific optimized
replacement schedule
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Page 29
Outline
• Introduction
• Operating experience
• Performance enhancement
• Repair solutions
• Life extension program
• Maintenance improvement
• Summary
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Page 30
SGT-800 Maintenance Plan
Maintenance Concept
MAINTENANCE
PREVENTIVE
MAINTENANCE
OPERATION
MAINTENANCE
MAINTENANCE
PLAN
 Daily attendance
 Routine maintenance
activities
 Time or cycle based maintenance
 Inspection and overhaul
 Remote diagnostic service
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CORRECTIVE
MAINTENANCE





Trouble shooting
Repair activities
Emergency spares
Emergency spare GT
24h service support
SGT-800
Easy on-site maintenance
 Modular build-up for easy
maintenance on site
 No need for special workshops
maintenance
 Gas turbine can be removed on
rollers through the sliding door
 Removable burners for quick and
easy inspection
 Vertically split compressor casing
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Maintenance Design Features
On-site Maintenance
•
All inspections and overhauls are
performed within enclosure
•
8 metric tonnes crane permanently
installed inside the gas turbine
enclosure
•
Minimum space requirements around
installation
•
No special transport or extra lifting tools
necessary
•
Modular design and vertical split
compressor casing for easy
maintenance access
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Page 33
SGT-800
Easy on-site maintenance
Hot section disassembly
Remove outer
and inner cone
1
Remove diffuser
casing
2
Remove turbine casing
Remove turbine
module and 1st guide
vane
4
Remove burners,
cone and combustion
chamber
5
3
Compressor disassembly
GT removal
On “rollers” to external
support structure
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Page 34
Maintenance Design Features
Off-site Maintenance – Single lift package
Turbine can easily be exchanged
with minimum space requirements
Turbine slides onto support
structure outside the enclosure
Support structure is towed out of
turbine hall
Turbine lifted from support structure
for further transport.
Weight of core 36 tons
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SGT-800 Single Lift Package
Maintenance Arrangements
SGT-800 Single lift
48 hours engine quick
exchange
Role out of engine on either side of
Turbine packages possible
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Page 36
SGT-800 Single Lift Package
Maintenance Options
 Exchange of core engine for off-site maintenance with maximized availability
 Transport of core engine or modules to local workshop for on-site maintenance
 Weather protection for handling of modules or a mobile workshop solution for core
maintenance that can be provided by customer, according to our specification
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Page 37
Remote Services
Customer support through remote monitoring & diagnostics
Remote Operational Services at
Siemens Industrial Application
Services that formerly required on-site visits are now
available via data transfer.
The complete spectrum of Siemens IP and O&G
Remote Operational Services is based on the
efficient, comprehensive and secure infrastructure of
the SIEMENS common Remote Service Platform.
Countries
STA-RMS* Platform
Service staff
Server
Farm
Firewall
PLC’s
Service staff
New Unit staff
Firewall
* STA-RMS =
Siemens Turbo Machinery –Remote Monitoring System
Today we provide:
 Remote Support
connection is used for checks or to solve problems
 Remote Updates
transfer SW to unit to update a control system
common Remote Service Platform
Firewall
Customer Plant
 Remote Monitoring
transfer operation data to central data base and
analyze it, e.g. Vibration, thermodynamics,
process data
Data Collector/Win CC
Remote Service enabling rotating equipment Life Cycle Cost reduction
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Page 38
Data
Base
SGT-800 Maintainability improvement
Development of Maintenance tools
Compressor dummy:
 reduces down-time
 improves safety
Turbine module tool:
 reduces down-time
 simplifies work
Gear box tools;
 reduces down-time
 improves safety
Universal table for stator part inspection:
 reduces down-time
 simplifies work
 improves safety
MGT Maintainability improvement results in Maintenance cost reduction
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Outline
• Introduction
• Operating experience
• Performance enhancement
• Repair solutions
• Life extension program
• Maintenance improvement
• Summary
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Page 40
Summary
 Enhancement programs are part of Siemens’ long-term product development
strategy and resulted in:
- Positive operation experience
- High reliability & availability
 Continuous improvements and modifications enabled:
- extension of engine life-cycle beyond 120,000 EOH (SGT-500, 600, 700)
- extension of maintenance intervals from 20,000 to 30,000 EOH (all MGT)
 Extended maintenance intervals from 20,000 to 30,000 EOH enable availability
improvement by 1 %.

 The life cycle & maintenance interval extension in combination with the
extended scope of component Reconditioning & Remote Services creates
additional opportunity for the operator to reduce their rotating equipment Life
Cycle Cost.
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Page 41
Thank you
for your attention!
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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
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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
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uncertainties arise, among others, from changes in general economic and business conditions, changes in
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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,
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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.
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