With
Rolls-Royce
Aero Engine
Technology
Engineered Solutions
siemens.com
2 / Engineered Solutions
Major Engineered Solutions
Offerings
Understanding the rapidly-changing nature of today’s
industrial and commercial environment
At Siemens we understand the rapidly-changing nature
of today’s industrial and commercial environment, in
which market requirements and operating conditions
can vary significantly - and often unpredictably. So we
design and shape our products and services to help
ensure Siemens customers maintain and increase
performance and profitability throughout the life of
their power generation or oil and gas project.
The long-term reliability inherent in Siemens equipment
means we have gained unrivalled experience and
knowledge when it comes to developing the engineered
modifications and upgrades that customers need to
sharpen their vital competitive edge by enhancing the
efficiency, environmental performance and profitgenerating potential of their equipment.
These engineered solutions from Siemens enhance your
total package, from the gas generator and its control and
ancillary systems through to the final driven equipment.
Siemens acquired the Rolls-Royce aero-derivative gas turbine and compressor business effective December 1, 2014. References to Siemens
and products are intended to refer to such business as acquired and incorporated into Siemens as from such effective date.
Engineered Solutions / 3
“We design and shape
our products and
services to help ensure
Siemens customers
maintain and increase
performance and
profitability
throughout the life of
their power generation
or oil and gas project.”
The Industrial Avon
The focal-point for three influential engineered solutions
This long-established aero-derivative gas turbine is the
focal-point for three influential engineered solutions
from Siemens, each delivering significant
enhancements to this robust and extensively used
gas generator.
Industrial Avon 200 upgrade
This modification offering cutting-edge technology
focuses Rolls-Royce Aero Engine technology on the turbine
section of the Industrial Avon. Results provide increased
power, efficiency, component life, reliability and time
between overhauls - without increasing the exhaust gas
temperature.
Swirler burner
This engineered solution enhances combustion stability by
directing compressor delivery air through the burner
nozzle exit faces and flame-tube swirler. This system which is standard equipment on the Industrial Avon 200 focuses on reducing the possibility of liquid hydrocarbon
carry-over from the gas fuel, ensuring smoother
combustion, extended discharge nozzle life and reduced
burner fouling, all of which improve availability. Increased
reliability and reduced overhaul costs also result from the
way this engineered solution minimises the effects of
high-cycle fatigue on turbine blades and discs.
Variable inlet guide vane closed loop control
Advances in materials, sealing, geometry and cooling
technologies deliver enhancements within the high-,
intermediate- and low-pressure turbine sections, while
combustion chamber improvements ensure improved
availability, increased reliability, reduced overhaul costs
and significant reductions in CO and CO2 emissions.
This engineered solution delivers enhanced control of the
Industrial Avon variable inlet guide vane (VIGV) system. It
provides closed-loop control and electronic switching that
exploits latest control technology to replace the current
mechanical system. By eliminating VIGV drift it maintains
gas generator efficiency while removing the possibility of
compressor surge. It also removes the need to check VIGV
position and blow-off valve settings during operation,
enhancing safety, while eliminating time-consuming
regular maintenance and improving reliability
and availability.
4 / Engineered Solutions
The Industrial RB211
The mainstay of a major global range of industrial
applications
With more than 650 Industrial RB211 gas turbine
systems sold worldwide and some 28 million operating
hours logged to date, the Industrial RB211 is the
mainstay of a major global range of industrial
applications - many of which are in remote or offshore
locations where high availability and reliability
are crucial.
Power is increased by up to 13% above -24C base load,
while reduced life cycle costs include reduced fuel burn,
extended time between overhauls and an improved
mechanical design eliminates weaknesses. Significant
reductions in CO2 emissions provide another key benefit.
Industrial RB211 engineered solutions from Siemens
include upgrades based on comprehensive system history
and key performance indicators established in our
technical support networks. These upgrades enable a
retrofit investment that enhances the customer’s
operation in key areas such as improved efficiency,
increased power, extended reliability, and cleaner
environmental performance - one or more of which can
give you that vital competitive edge.
This engineered solution lowers emissions by replacing
the combustor assembly module with nine radial
combustors, fuel valves and associated piping. This
upgrade exploits latest lean-burn combustion technology
and supplies fuel through three manifold systems. Full
low-NOx and low-CO capability is achieved by
this conversion.
Industrial RB211-24C to -24G upgrade
This engineered solution gives the option of increased
power and improved heat rate or increased life when
operating at RB211-24C ratings. Replacement turbine
components feature directionally-solidified blades with
improved cooling, advanced aerodynamics and improved
seals allowing higher firing temperatures, which help
increase power and improve heat rate. If used at -24C
firing temperatures, these materials provide extended
component life.
Industrial RB211-24C/G to 24G DLE upgrade
The success of the Industrial RB211-24G in the market is
emphasised by the presence of nearly 300 units in service
worldwide, with combined operational experience of
nearly 10 million hours - and the lead engine with
100,000 hours. Nearly 60 -24C rated Industrial RB211’s
have received the -24G upgrade, with the lead engine
accumulating more than 70,000 hours since conversion.
Engineered Solutions / 5
“This engineered
solution lowers
emissions by replacing
the combustor
assembly module with
nine radial
combustors, fuel valves
and associated piping.”
Gzero upgrade
Electric start conversion
Up to 10% more power can be achieved by upgrading to a
modified intermediate-pressure compressor equipped
with an extra stage of blades at the front (a zero-stage).
This engineered solution also matches the flow capacity
of the power turbine to the increased gas
generator output.
This upgrade replaces existing high-pressure natural gas
starter systems with a simpler, more robust electric motor
that has worldwide voltage capability. Benefits include a
reduced design complexity that delivers a minimum
overhaul/service life of 20 years, better reliability, easier
maintenance, reductions in emissions and noise and
considerable savings in maintenance costs over a 25-year
life cycle of an electric starter.
Dual fuel conversion
This engineered solution increases the flexibility of
Industrial RB211 units operating in power generation and
oil and gas applications. It gives the option of running the
engine on either gas or liquid fuel, while fuels can be
switched during steady-state running of the gas
generator. The upgrade eliminates the risk of interruption
or depletion of the gas generator’s fuel supply. It also
provides a black start capability.
Today more than 80 units are operating with this dual fuel
capability, with combined experience of more than three
million hours.
6 / Engineered Solutions
The Industrial 501
Popular, proven and profitability-enhancing
engineered solutions
Two popular, proven and profitability-enhancing
engineered solutions are available to operators of
Siemens Industrial 501 generating sets worldwide, the
upgrade from KB5 to KB5S standard and the DLE fuel
system upgrade.
Industrial 501-KB5 to KB5S
This superior Industrial 501-KB5S specification improves
the heat rate and increases the output power of the
Industrial 501 package. By replacing the KB5 rear turbine
bearing support and fourth-stage turbine blades, this
engineered solution increases power output by up to 4%
without the need to raise firing temperatures, while the
heat rate can be improved by up to 6%. The work is
undertaken during overhaul of the gas generator.
Dry Low Emissions (DLE) conversion
Advanced lean-burn combustion technology reduces NOx
and CO emissions without the need for water injection.
Available for gas-fuelled Industrial 501 installations, the
dry low emissions engineered solution ensures ignition
and part-power operation is performed by use of the pilot
fuel circuit, while full-power operation is achieved solely
on the main fuel circuit. Emissions levels of 25 vppm of
NOx and 50 vppm of CO are achievable.
More than 100 DLE systems have entered service in recent
years and customers include Triger Cinergy (with five
units), Florida Gas (five units) and Pacific Gas & Electric
(four units). This engineered solution is delivered during
routine overhaul of the Industrial 501.
Engineered Solutions / 7
“With RT48 power
turbines, conversion of
open-bladed stages to
RT48S shrouded blade
design enhances
efficiency and
improves blade
vibration damping.”
Power Turbines
The latest in mechanical and aerodynamic
improvements
Mechanical and aerodynamic improvements, latest
component technologies and refurbishments to ‘as
new’ condition are among the Siemens engineered
solutions aimed at extending the effectiveness of
customers’ power turbines. For example, RT56
packages can be upgraded to RT62 by changing the
power turbine (which shares the same footprint and
centre line) to unlock the existing additional power
available from the same Industrial RB211 engine.
RT48 to RT48S and RT56 to RT62 conversions
These conversions use latest-technology components to
increase power and improve heat rate. They also deliver
the benefit of a ‘zero-hour’ upgrade, in which the unit is
returned to as-new condition. With RT48 power turbines,
conversion of open-bladed stages to RT48S shrouded
blade design enhances efficiency and improves blade
vibration damping. Rated speed can be increased to
realise full efficiency and an increase in power.
RT56 and RT62 T-PIN to curvic rotor upgrade
RT48S/RT56/RT61 zero hour refurbishment
This engineered solution ensures the second-stage disc
rotation is transferred to its shaft by a curvic coupling that
replaces the existing T-pin coupling - an enhancement
that reduces rotor vibration and enhances availability.
RT56 / RT62 hot match conversion
This engineered upgrade replaces first-stage vanes with
new components, increasing the turbine’s throat area and
helping to improve performance in hot conditions.
This engineered solution provides the customer with a
new set of discs and blades that bring the benefits of
running the rotor in ‘as-new’ condition. The RT56 / RT62
upgrade enables the operator to run another 100,000
hours without major overhaul.
8 / Engineered Solutions
Compressors
The focal-point for three influential engineered
solutions
You can match your compressor operation to changes
in operating conditions by undertaking a re-aero of
Siemens pipeline and barrel centrifugal compressors.
At considerably less than the cost of a new compressor,
Siemens can rework the aerodynamic bundle to meet
new site conditions and restore it to full operational
efficiency. Dry Gas Seal (DGS) upgrades bring benefits
too by eliminating problems with the high-pressure
seal oil system. Better operational performance and
higher corrosion resistance add to the value.
Re-aero / aerodynamic / assembly replacement
By upgrading the aerodynamic bundle you can gain
greater operational efficiency and extend the head,
capacity and operating envelope - for considerably less
cost than a new compressor. New components, often steel
machinings to replace castings, deliver significant
improvements. Efficiency improvements of up to four
percentage points can be delivered by better design and
manufacturing techniques.
Dry gas seal conversion
This engineered solution enhances the compressor sealing
system and eliminates problems linked to high-pressure
oil-based sealing systems. It eliminates oil contamination,
saves energy by reducing parasitic losses caused by oil
seal pumps and removes the need to dispose of used oil.
Maintenance costs and downtime are also reduced.
Low leakage wet seal upgrade
This upgrade reduces the potential for oil leaks in
compressors by using wet seals. A Kaydon seal (a liquid
buffered oil bushing seal with low leakage and high
reliability) in a cartridge assembly is fitted to ensure
reduced oil leakage.
Engineered Solutions / 9
“At considerably less
than the cost of a new
compressor, Siemens
can rework the
aerodynamic bundle to
meet new site
conditions and restore
it to full operational
efficiency.”
Controls
Engineered controls solutions improve your equipment’s
reliability
Engineered controls solutions improve your
equipment’s reliability by replacing obsolete controls
with new and improved systems. This enhances system
diagnostic trending and brings benefits of remote
operation and data acquisition.
Option selection based on operational need, equipment
vintage and allowable downtime for replacement.
Quickest replacements are achieved via modular upgrade
and have been completed within 7-9 days with planning
and teamwork between the customer and Siemens field
service teams.
FT125 control system upgrade
This influential engineered solution is ideal for Industrial
501, Industrial Avon and Industrial RB211 packages. Based
on a programmable logic controller with remote I/O’s
(Inputs/Outputs), the FT125 is suitable for both new and
retrofit applications. It can be used as a stand-alone
engine control system, interfaced to a central diagnostic
maintenance system or to a central plant control system.
The FT125 offers the benefit of availability of extensive
information for equipment diagnostics and preventative
maintenance, while protecting your equipment to ensure
improved availability and reliability.
Complementary upgrades to vibration monitoring, surge
control and generator control and protection are
also available.
FT210 HMI and FT310 upgrades
These complementary upgrades along with the FT125
upgrade are also available which bring the software and
hardware of the Health Monitoring Instrumentation
computer and the engineering work station to the latest
standard and configuration.
Fuel control system upgrades
Siemens has developed a variety of control system
solutions. It is important to select the most appropriate
solution for your needs. Three types of upgrades
are available:
•Full panel upgrade
•Sub plate replacement
•Bolt-in/plug-in modular replacement
Siemens engineered solutions can assess your current fuel
delivery system and provide you with the most modern
and robust system updates. For example, our electricallyactuated metering valves meet demands in gas turbine
flow accuracy and are responsive to transient
requirements, including those for low-emission gas
turbine uses.
10 / Engineered Solutions
North America
(NA)
Europe
Russia
& Africa
(ERA)
Middle
East &
Central Asia
(MECA)
Asia-Pacific
(AP)
South America
(SA)
The Package
Engineered solutions deliver a broad range of package
improvements and upgrades
Siemens engineered solutions deliver a broad range of
package improvements and upgrades, including
restoring your power and efficiency in high ambient
temperatures, increasing the functionality and
reliability of your fire and gas protection systems and
improvements to air inlet filtration system to extend
operational life and increase air flow.
vintage Industrial RB211 engines. The scope of supply
involves an on engine hydraulic starter motor plus a
completely independent hydraulic starter skid which has
an electric motor driven pumps and manifold assembly.
Additional pump assemblies rated at 3 x 50% power can
be supplied as an option to increase unit hot sparing and
redundancy.
GG Lube Oil System Upgrade
Inlet fogging system upgrade
The GG Lube Oil system upgrade is applicable to all
Industrial RB211 and Industrial Avon gas generators
model. This upgrade provides the latest standard lube oil
system design for Oil and Gas and Power Generation
customers with a free standing state-of-the-art lube oil
console. The new Lube Oil System can be an external skid
mounted next to the Gas Turbine package or alternatively
integrated within the package itself. Various retrofit
solutions such as sharing of the same oil reservoir for the
Hydraulic Start systems for Industrial RB211 to the new
Lube Oil Console is available to maximizes your unit
availability and reliability.
This system comprises a pump unit with dispensing
nozzles placed in the combustion air inlet duct
downstream of the air filter. It provides up to 14ºC of
cooling effect thus providing a power boost on hot
ambient days. Its demineralised water supply is available
from an optional water treatment skid. This upgrade is
installed at your site.
Hydraulic Start System Upgrades
The Hydraulic Start System Upgrade is applicable to all
Industrial RB211 gas generators models. This upgrade
provides a completely new close loop hydraulic start
system that incorporates the latest technology in the
market today and also addresses the older obsolete
components of the hydraulic starter systems on all older
Fuel metering valve and motor controller upgrade
The old standard hydraulic fuel valves and motor
controllers can be upgraded to the latest standard and are
offered as an optional complementary upgrade to the
FT125 controls system upgrade.
Fire and gas detection/suppression system upgrades
This engineered solution uses latest technologies in fire
and gas detection. It revises your package’s suppression
system to conform with local environmental regulations.
Engineered Solutions / 11
“The old standard
hydraulic fuel valves
and motor controllers
can be upgraded to the
latest standard and are
offered as an optional
complementary
upgrade to the FT125
controls system
upgrade.”
Machinery protection, availability and reliability is
improved and systems have on-board diagnostics.
Inlet air filtration upgrade
Multiple filter options extend operation life and increase
air flow. Replacement units for normal unit operation,
plus enhanced systems that cope with rapid
contamination in harsh environments are the available
options. This engineered solution provides high protection
from fine particles and extends unit performance by
preventing environmental deposits on the inlet housing
and compressor rotor. Low-cost turbine protection is
gained while compressor fouling and erosion is reduced,
increasing your unit’s availability and its mean time
between overhauls.
Regional Sales Offices
Europe, Russia & Africa
The Iceni Centre, Warwick Technology Park
Warwick CV34 6DA, United Kingdom
Tel: +44 (0) 1926 306000
Tel: +44 (0) 1926 306000
South America
Av. Almirante Barroso 52, 9th Floor,
20031-000, Rio de Janeiro, Brazil
Telephone: +55 21 2277 0100
Fax: +55 21 2277 0168
Middle East & Central Asia
Siemens Energy
Ground Floor, Block 6, SAF 2, Masdar City
Abu Dhabi
United Arab Emirates
Tel : +971 2 616 5100
North & Central America
Asia, Far East & Australasia
8303 McHard Road
Houston, Texas 77053 USA
Telephone: +1 281 436 6700
Fax: +1 281 436 6777
Singapore Siemens Pte Ltd
The Siemens Center
60 MacPherson Road
Singapore 348615
Tel : +65 6490 6000
Published by and copyright © 2014:
Siemens AG
Power and Gas
Freyeslebenstrasse 1
91058 Erlangen, Germany
For more information, please contact
our Customer Support Center.
Phone: +49 180 524 70 00
Fax: +49 180 524 24 71
(Charges depending on provider)
E–mail: support.energy@siemens.com
Order No. E50001-G510-A250-X-4A00
WS 1114
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All rights reserved. Trademarks
mentioned in this document are the
property of Siemens AG, its affiliates, or
their respective owners. Product Mark
501 is a trademark of and used under
license from Rolls-Royce plc.
Subject to change without prior notice.
The information in this document
contains general descriptions of the
technical options available, which may
not apply in all cases. The required
technical options should therefore be
specified in the contract.