Published by and copyright © 2008:
Siemens AG
Energy Sector
Freyeslebenstrasse 1
91058 Erlangen, Germany
Siemens Energy, Inc.
4400 Alafaya Trail
Orlando, FL 32826-2399, USA
For more information, 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
Energy Service Division
Order No. E50001-G5100-A100-V1-4A00
Printed in Germany
Dispo 05400, c4bs No. 1386 P WS 10082.
All rights reserved.
Subject to change without prior notice.
Printed on paper treated with chlorine-free bleach.
Trademarks mentioned in this document are
the property of Siemens AG, its affiliates, or their
respective owners.
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.
Dedication to efficient service
Sustainable planning, consulting and service solutions for industrial applications
www.siemens.com/energy
Answers for energy.
Services to support your
plant performance and profit
Training & Consulting
Our range of training programs support your
plant’s full life cycle. They include on-the-job
training, classsroom-based training and in-plant
training on our stimulators or at our training
facilities under realistic conditions.
Implementing
Project management is our specialty. Our experience
gained in hundreds of successful projects enables
us to plan each implementation step exactly.
And we never leave the customer until everything
is up and running properly.
Operating
You can either run your plant yourself - or let us run
it for you. We offer operating services to match your
strategic business needs. You define the level of
everyday support. We even provide the plant staff
and fully operate the plant. We run many plants
around the world.
Maintaining
Regular inspections help recognize conditions which
require maintenance or repairs at an early stage.
Our services, such as non-destructive examination
techniques, are developed for quick analysis
and enable intelligent decision making that can
help to cut your costs significantly.
Our performance helps to improve yours
The driving force behind Siemens Energy Service division is a dedication to speed of response and customer
intimacy. This is because the goal is to deliver sophisticated energy services fast. Services that are designed
to fit your plant‘s performance needs and your business goals perfectly.
Our global network plays a central role in helping us meet this commitment. We are present in 161 countries
worldwide and our six Product Lead Centers and 18 Service Shops offer the world-class logistics to deliver fast
and effective results.
We do not just offer rapid response and proximity, we also offer our customers personal closeness.
We want to really get to know our customers and their personal and technical needs. This makes it easier for us
to understand problems, find solutions and, above all, deliver help and support more efficiently.
Repairing
Changing and repairing components is a routine job.
Our goal is to help you stop operating issues
from becoming outages. We are helped by incidents
diagnostic systems - and our experience.
All our efforts focus on keeping your plant online
or putting it back on the grid as quickly as possible.
Modernizing
There are various ways of maximizing plant
efficiency. For instance, you can increase output
without using more fuel and you can turn an oldertype plant into a modern one. Our modernization
solutions are known for their effectiveness in terms
of business success and environmental impact.
Extending Lifetime
When plants reach their designed lives, safety
and availability decrease. Our metallurgical,
integrity and fracture mechanics analyses reveal
the real state of your plant and enable adequate
lifetime extension measures - important assets
in the deregulated electricity market.
Choose the service that is right for your business from our comprehensive portfolio.
2
3
Our goal is to overcome market
challenges every day
Engineering excellence with unique market insight
Service for Compressors
The energy market is becoming increasingly
complex and challenging. Costs are rising
and governments are tightening legislation,
creating economic and political obstacles
to achieving and maintaining plant profitability. At the same time, demand for energy
is at its highest level ever, increasing the
pressure for maximum output.
Service for Generators
We at Siemens understand that you need
to get the most out of your plant every day.
We are dedicated to removing unscheduled
downtime and keeping scheduled
downtime to a minimum. Our certified
processes are designed to ensure that
each plant component, from the smallest
valve to a complete turbine, functions at
maximum capacity. In addition, our
worldclass logistics help you react to and
deal with today’s challenges faster.
Helping you plan for tomorrow‘s market is
another of our core service commitments.
We focus on long-term operational flexibility,
putting you and your plant in the perfect
position to adapt to future industry developments, take advantage of new energy
opportunities and respond to potential
challenges.
Service for Steam Turbines
Service for Medium Gas Turbines (MGT)
Service for Small Gas Turbines (SGT)
4
5
Nothing is faster
than already being there
Fast service for safer planning
In today‘s fast-moving world, it is even
more important to have a partner you can
rely on to deliver support and assistance
immediately. Whether a valve has to be
replaced or a turbine has broken down,
our global network has the resources to
respond fast and effectively, anywhere in
the world. We are present in 161 countries
worldwide and have 18 Service Shops
around the globe, all manned by local
experts who are dedicated to getting
your plant back on the grid as quickly as
possible and preventing such incidents
from happening again.
6
Siemens’ assistance is only a phone
call away. Around-the-clock emergency telephone service is manned
by a team of operational support
specialists. They are ready to provide
assistance in the running of
your plant.
It is not just geographical proximity that
enables us to respond quickly. Our dedication
to establishing close customer relationships
helps us understand and anticipate your
plant‘s operational and equipment needs
inside out. Which, in turn, enables us to
effectively implement certified processes
designed to improve quality and streamline
functionality, thus saving you valuable time.
7
To know is to understand
Closer to your business
No two plants are the same. Each has
specific technical, operational, financial
and environmental needs. Which is why
we at Siemens Energy Service encourage
you to share your values, aims and
individual requirements with us, enabling
us to understand what makes your plant
different. This gives us access to unique
insights, enabling us to spot weaknesses,
identify hidden potential and enhance
both short and long-term performance.
ding
ten e
Ex fetim
Li
Trai
Con ning
su &
lti
n
lementing
Imp
Modern
izin
g
g
ri n
in
ai
g
Rep
An added benefit of building close
working relationships is that you are
assigned a dedicated service team to
work directly with you. This gives you
a single point of contact, be it a replacement parts professional to advise you on
delivery and installation or the project
manager responsible for running your
entire plant.
at
g
Ma
in t ainin g
Op
er
Siemens Energy Service offers you
a wide range of opportunities.
Whether you need an immediate
part replacement or are planning
a long-term operation such as the
performance enhancement of a turbine. We can also offer you several
maintenance contract options. You
decide when and how often to take
advantage of our support. This is
possible throughout a product‘s entire
lifecycle or for certain phases.
We can offer you the exact service
to fit your requirements perfectly.
Service program for client A.
Service program for client B.
8
9
Turning good into better
Performance Enhancement Programs
Improving your plant‘s performance
does not have to be costly or time consuming. Just a small change can make a
huge difference: it is all about choosing
the right one. We at Siemens are committed
to finding cost-effective and efficient
ways to improve your processes, maximize
your output and lower your environmental
impact.
We plan and undertake extensive plant
inspections and operational analysis to
identify enhancement potential.
Our performance enhancement programs
include introducing low maintenance
components, upgrading hardware,
optimizing workflows or modernizing
computer interfaces. In addition, finding
ways to reduce emissions and improve
performance is one of our main service
priorities.
10
In a performance-based market
structure, where plants are managed
as profit centers, it is necessary to
strategically improve efficiency,
optimize capacity, minimize costs
and maintain high reliability in
order to be competitive.
Effective and accurate maintenance planning
is also crucial to getting the most out of a
plant. Our in-depth knowledge of your
equipment allows us to anticipate repair
works and plan timely intervention,
reducing unnecessary downtime. We also
closely monitor equipment and machinery,
enabling us to identify the best time to
upgrade them to meet changing market
developments. By simply planning ahead,
we can help make an aging plant match
the competitive performance of a new
one for years to come.
11
Identifying faults before
they become failures
Corrective & Performance Maintenance
One of our major service goals is to keep
your downtime and subsequent loss of
productivity to a minimum. Rather than
wait for complications to occur – from
the tiniest defects to potential worstcase shut down scenarios – we act preemptively to prevent them happening.
Once our advanced remote monitoring
and diagnostic services have identified
the issue, our team of specialists are then
able to plan and advise on necessary
action in advance.
Some repairs and service work are
unavoidable. But we have the processes
and expertise to ensure that necessary
repairs do not slow you down. Working
closely with you, we anticipate potential
maintenance requirement and plan time
and cost effective ways to implement
them. Whether it is replacing a defective
valve, unblocking a pipe or overhauling
a turbine, we are the partner you can rely
on for fast, effective and comprehensive
maintenance that will not affect your
productivity.
Siemens Energy Service assembles a
regional team of experts that works
directly with you to determine your
needs. By utilizing advanced project
management, supervisory and scheduling techniques to coordinate all
required activities, we are able to
oversee the successful completion
of turbine-generator maintenance
projects.
Waiting for replacement parts can also cause
unnecessary delays. Our comprehensive
replacement parts service keeps up the
levels of your stocks, guaranteeing fast
delivery and removing the need to tie up
capital in in-house storage.
We will even assign you a parts professional to help track your parts and oversee the process. It is all about having a
service provider who can get the right
part to the right place at the right time.
12
13
Finding the right options for you
from a world of choices
Service Programs
By opting for a Siemens service program,
you are choosing the reassurance of a set
timeframe and budget. You also have
the peace of mind of assigned personal
points of contact as well as agreed
planning procedures and maintenance
routines.
Regardless of whether your service
requirements are big or small, Siemens
can proactively boost your plant‘s longterm performance with a variety of
customizable options to fit your individual
needs, both technical and financial.
For example, our long-term gas turbine
program has proven particularly effective
in helping plants around the world effectively
manage and reduce downtime.
14
We are able to respond rapidly with
replacement parts. This is because
we stock 23,000 styles and over
4 million parts in the central parts
warehouse, ready for same-day
shipment 24 hours a day, 7 days
a week.
15
Giving you the power
of knowledge
Training & Consulting
We at Siemens understand that knowledge is one of the most important tools
in the industry and that it can give you
a clear competitive advantange. Welltrained staff who can face any challenge
are vital to operating your plant efficiently and productively.
That is why the Siemens Power Academy
offers a wide range of customized training
programs for plant management, operation
and maintenance. Training is available
on site, online or at our state-of-the-art
training facilities including real-life simulators for worst case scenarios. Our wide
range of training courses caters for every
stage in a plant‘s lifecycle, covering in-depth
and essential equipment and systems
knowledge, preventing or carrying out
repairs, as well as health and safety.
16
No amount of theory can replace
learning by doing. Which is why we
focus on both, classroom and handson-training to provide more learning
opportunities.
We also offer a comprehensive range of
tailor-made consulting services, such as
advice on building new plants, extending
your plant‘s lifecycle, cost-effective operation, safety and environmental issues and
much more. Siemens is the partner to
consult if you want to take your plant
forward.
17
References
Creating success stories
by working together
At Siemens, we have a long tradition of
building successful client relationships.
Based on mutual understanding and
respect, these relationships play a key
role in helping us meet our clients‘ specific
needs and individual requirements.
This in-depth knowledge, combined with
our unparalleled expertise, facilitates
solutions to even the most complex tasks
such as regenerating aging turbines.
We also make it a priority to deliver these
solutions with minimum downtime.
18
The three reference projects are perfect
examples of our operational flexibility
and goal-oriented processes.
Customer
Customer
Customer
Morgan Stanley
LyondellBasell Industries (former BP Plant),
Münchsmünster, Germany
INEOS Köln (also known as EC ErdölChemie
or BP Köln and Innovene)
Background
Background
Background
When Morgen Stanley took over the Berkelcentrale cogenerating station in Holland,
they were looking for a reliable and flexible
partner with the engineering solutions to
meet their requirements.
LyondellBasell Industries needed to upgrade
an aging steam turbine to extend its operating
life and improve efficiency.
INEOS Köln ordered a large-scale shutdown of the
Kracker 5 plant. This required meticulous planning
to keep downtime to a minimum while extensive
work took place such as replacing parts and
carrying out large and small-scale overhauls.
Product
Product
Product
Gas Turbine
SGT-600 a brand new gas generator (GG)
combined with the existing power turbine
(PT).
Steam Turbine
3 trains: a footprint turbine with 2 footprint
compressors behind it, an ethylene train and
a propylene train.
Compressor and Steam Turbine.
Scope
Scope
Scope
Refurbishment/upgrade of an older unit with
a high number of start-stop cycles to meet
the new operating profile. Upgrade of the
combined heat and power plant for maximum operating flexibility to maximize revenues from power sales in an unpredictable
wholesale market.
Siemens had stored all original data and was able
to produce a footprint for the machines.
With this footprint the downtime could be kept
to the bare minimum. In this case, footprints
were created for two new Steam Turbines and
one raw gas compressor train.
There were two years of preparation work with
a team of ten for the preparation phase.
The cooperation of different Product Lead
Centers and 45 people in two shifts working
together at INEOS Köln in the overhaul phase
was needed to replace a gas turbine with a body
turbine and to do small-scale and long-scale
overhauls for ten different machines.
Result
Result
Result
The operating life of the two gas turbines
was dramatically extended.
The expertise to create footprints for the existing
machines facilitated the successful completion
of the project.
Completed with a minimum downtime
of only 6 weeks according to schedule.
19