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