Update on Siemens 8000H CCPP Technology and Operational
Experience
Authors:
Dr. Kais Sfar
Siemens Energy, Head of Product Line Marketing Plant Solutions
Armin Staedtler
Siemens Energy, Head of 8000H R&D Program
PowerGen Asia
Bangkok, October 3 – 5, 2012
1
Abstract
More than one year ago, the start of commercial operation of “Ulrich Hartmann” power
plant in Irsching (unit #4, Germany) marked the dawn of a new era in combined cycle
power plant construction. For the first time the magic figure of 60% efficiency was
topped. However, not only this world-record efficiency level sparked the interest of the
power generation community, but also the successful optimization of the plant’s
operational flexibility. The high level of plant flexibility is setting benchmarks and
enabling an operating regime, which today already meets the rising demand of the future.
Rapidly increasing share of renewables-based power generation and high fluctuating load
demand – especially in small grids – will require combined cycle power plants able to
provide highest performance at base and part load and at the same capacity for fast
cycling and grid support. Initial tests already demonstrated that the plant exhibits
excellent characteristics in terms of grid stabilization. It was also demonstrated that the
FACY ™ package developed by Siemens enables startup times of less than 30 minutes.
This paper describes Siemens answer to the different regional market requirements and
focus on both the SGT-8000H gas turbine series and the corresponding combined cycle
power plant solutions for the 50Hz and 60Hz regions. The market introduction of the
8000H class technology was based on an extensive validation and test strategy first in
Irsching for the 50Hz frame under real field conditions and later for the 60Hz frame,
which is a direct scale of the SGT5-8000H, in the Berlin test facility. This paper will
further summarize all field validation activities and results, showing how Siemens is
bringing the 8000H to the market based on a comprehensive approach to ensure a risk
minimized market introduction. Finally this paper will describe the current commercial
experience and the first references within the 50Hz and 60Hz markets.
2
Table of contents
1. The challenge – Fluctuating power demand at raising
fuel costs
4
2. Siemens 8000H combined cycle power plant solutions
8
2.1.
SGT-8000H gas turbine: Proven design with highest efficiency & flexibility
2.2.
SCC-8000H combined cycle power plant solutions
8
13
3. Operational experience
19
3.1.
Test and validation of the SGT5-8000H and SCC5-8000H
19
3.2.
Test and validation of the SGT6-8000H
23
4. Market launch and first commercial references
27
5. Conclusion
29
6. References
31
7. Copyright
33
8. Disclaimer
33
3
1. The challenge – Fluctuating power demand at raising fuel
costs
Considering the worldwide trend of increasing demand for eco-friendly power
generation, a major concern to power producers aiming to build new plants is to
understand the impact of the long-term CO2 reduction targets on the power generation
market of today and the future. Despite all uncertainties related to the potential future
changes in regional environmental policies and CO2 reduction targets, today’s power
plant solutions must be capable of running profitably throughout the whole service life,
which in the case of combined cycle power plants is typically more than 20 years.
Customers expect environmentally-compatible and economical state-of-the-art solutions,
which offer a maximum value and long-term investment security, even in a volatile
market environment.
Driven by stringent CO2 reduction targets, the share of renewable energy resources is
rapidly growing. The analysis of the predicted residual load, which is the difference
between incoming renewables-based power supply and power consumption, shows an
extremely fluctuating course over the year. Based on further statistical analysis a clear
shift of the fossil power plants' operating regime from base load towards intermediate
and peak load is predicted. Also, the remaining conventional power plant fleet has to be
able to cope with much higher load ramps and therefore partly serve as backup, e.g. in
case renewables feed-in is interrupted, on short notice.
Considering the ASEAN region, which is characterized by strong economic growth, a
continuous increase of power demand of approx. 6% per annum is anticipated over the
upcoming years. Accordingly, new generating capacities will have to be built to meet this
increase in the years ahead. Inversely to Europe, renewable energy power generation in
the ASEAN region is still limited and plays a secondarily role within today’s energy mix.
Nevertheless, it is clearly expected that in future the renewable power generation share
will increase. Therefore new future power plant investments have to consider renewable’s
impact at a very early stage of the planning process.
Since natural gas availability in the region is growing, e.g. through the continuous
4
extension of the LNG terminals network around the South Pacific Rim, gas fired power
generation plays a key role in securing the energy supply of the region.
Thanks to their outstanding dynamic characteristics, combined cycle power plants are
able to offer highly flexible solutions that can accommodate sharp daily fluctuations in
power consumption. Operational flexibility is based mainly on three major aspects:
–
Operational efficiency comprising highest efficiency throughout the whole load
range and optimized start-up and shut-down operation
–
Power on demand comprising rapid availability by fast starts and load ramps
–
Grid support, also comprising load ramps, stable operation in case of grid
incidents and backup power
Since gas fired power plants represent a major portion of the energy mix, it is clear that
this type of plant is used to cover a certain portion of the base load needed in the region.
During this load regime highest efficiency is a key requirement to drastically reduce fuel
consumption and, of course, reduce CO2 emissions.
5
Siemens combined cycle power plants are addressing
the major environmental and economical market drivers
Ecological
awareness
Gas prices
Lowest investment
Operational flexibility
Highest efficiency
+
+
Steep load ramps
and fluctuating
power demand
Bangkok, Oct. 3 – 5
PowerGen Asia 2012
© Siemens AG 2012
Siemens Energy Sector
Figure 1 Major power plant requirements
The evaluation of the different regional requirements (Figure 1) as discussed earlier leads
to the following key drivers:
–
Investment: lower specific investment (EUR/kW) resulting from economies of
scale, while achieving highest reliability and availability.
–
Performance: increase combined cycle net efficiency to over 60% with a power
output over 550 MW in a 1 on 1, while drastically reducing emissions.
–
Operational flexibility: reduce startup and shutdown times, increase load ramps
for fast load-following ability, improve turn down capability, part-load efficiency
and startup reliability.
These factors have been considered by Siemens Energy in the development of the new
H-Class gas turbine SGT-8000H series and the combined cycle power plant, the SCC8000H series, taking both environmental protection as well as economical focus into
consideration. The 8000H program was started in 2000. It was dedicated to consistently
implementing our engineering know-how not only for the gas turbine but also for the
6
overall plant solution. Thus, Siemens Energy can provide the right answer to tomorrows’
energy supply needs already today.
7
2. Siemens 8000H combined cycle power plant solutions
2.1.
SGT-8000H gas turbine: Proven design with highest efficiency &
flexibility
Following the merger of Westinghouse Power Generation with Siemens in 1998, the
decision was made to develop a Next Generation Family of Gas Turbines and therewith
widen the existing product portfolio based on the H class frames for 50Hz and 60Hz
markets (Figure 2). The SGT-8000H series addresses the major market requirements in
terms of efficiency, environmental protection, operational flexibility and economical
value.
Siemens Large Scale Gas Turbines:
Product Portfolio for 50 Hz and 60 Hz
SGT5-8000H
375
292
SGT5-4000F
274
SGT6-8000H
SGT6-5000F
200
168
SGT5-2000E
113
SGT6-2000E
Output in MW @ ISO conditions
Bangkok, Oct. 3 – 5
PowerGen Asia 2012
© Siemens AG 2012
Siemens Energy Sector
Figure 2 Siemens Energy large scale gas turbine product portfolio
The SGT-8000H gas turbine series combines the best design features and technologies of
the established product lines with some technology innovations and enhancements and is
the result of a continuous optimization and harmonization development activities. The
functional and mechanical design of the engine was built on the extensive experience
8
gathered over decades with the predecessor 50Hz and 60Hz engines of both companies
Siemens and former Westinghouse. Proven design features were applied wherever
possible, and “Design for Six Sigma” tools were used throughout the process, to deliver a
robust product which meets all requirements (Figure 3). The results of the 8000H
development, testing and validation activities were also used as an enabler for the
different F class engines upgrades.
SGT-8000H engine concept
based on harmonization and new technology
Siemens V Design
ƒ Single tie bolt
ƒ Compr. stat. design
Harmonized
Compressor
Siemens W Design
ƒ Turbine cylinder
ƒ Turbine vane carrier
ƒ Exit housing
ƒ Front hollow shaft
ƒ Bearings
ƒ Compressor cylinder
ULN can-annular
combustion system
ƒ Turbine features
ƒ Turbine diffuser
Secondary Air
System
The SGT-8000H concept uses proven features from Siemens and (former)
Westinghouse engines and introduces new technology
Bangkok, Oct. 3 – 5
PowerGen Asia 2012
© Siemens AG 2012
Siemens Energy Sector
Figure 3 Concept of the SGT-8000H series
Based on the SGT-8000H frames different packages and plant product configurations
for both 50Hz and 60Hz markets were developed (Figure 4). A detailed plant solution
view will be discussed in the next chapter.
9
Configuration and Performance Overview
SGT-PAC 8000H
SCC-PAC 8000H 1S
SCC-PAC 8000H 2x1
50 Hz
60 Hz
375 MW
40 %
274 MW
40 %
570 MW
60 %
410 MW
60 %
1.145 MW
60 %
824 MW
60 %
---
1.236 MW
60 %
SCC-PAC 8000H 3x1
at ISO conditions
Bangkok, Oct. 3 – 5
PowerGen Asia 2012
SGT5/6-8000H
SCC5/6-8000H 1S
SCC5/6-8000H 2x1
© Siemens AG 2012
Siemens Energy Sector
Figure 4 Configuration and performance overview
The basic engine design is summarized in Figure 5 and has the following features, which
account for the high efficiency and the increased operational flexibility: The SGT-8000H
series is an integrated product line with common features and an evolutionary design.
–
The engine uses the well known SGT5-4000F disc-type hollow-shaft rotor with a
single tie bolt. The discs are interlocked and centered using Hirth couplings. This
shaft design has smooth and stable running behavior due to the low weight with
high stiffness and uniform thermal expansion under all operating conditions.
Siemens has over 16 Million EOHs and more than 750 gas turbines operating
with this type of rotor.
–
The 13 stages high efficiency axial compressor is Siemens harmonized design,
which is offered on the SGT6-5000F as well as the SGT-8000H engines. This
design has four variable guide vanes to maintain high part load efficiency and low
emissions. This design continues to offer the ability to replace blades without a
10
rotor lift. The 50Hz and 60Hz versions are conceptually identical and are
geometrically scaled.
–
The can annular combustion system design is based on the SGT6-5000F and is
purely air-cooled. The existing Siemens fleet with over 400 operating units offers
more than 8,500,000 EOHs of extensive experience with this type of combustion
system. Both 50Hz and 60Hz SGT-8000H engines have a common combustor
assembly.
–
The turbine part of the engine consists of four high efficiency stages with aircooled turbine blades. Blade R1 uses directionally solidified material and
enhanced TBC system. There is no need for single crystals use and steam cooling.
The first stage blade and vane are removable through the combustor without
cover lift. Further measure for improved serviceability and shorter outages is the
use of a single turbine vane carrier. Similar the SGT5-4000F the turbine has a
conical flow path, which allows for hydraulic clearance optimization.
SGT5-8000H
Efficient & Flexible
Advanced Can Annular
combustion system
Evolutionary 3D blading
4 stages of fast acting variablepitch guide vanes (VGV) allowing
for improved part load efficiency
and high load transients
> 60% combined
cycle efficiency
Proven rotor design
(Hirth serration,
central tie rod, internal
cooling air passages)
for world class fast
(cold) start and hot
restart capability
3D Four stage turbine with
advanced materials and
thermal barrier coating
High cycling capability due
to fully internally air cooled
turbine section
Transient protection of clearances
for reduced degradation with
hydraulic clearance optimization
(HCO) active clearance control
HCO for reduced
clearance losses
Performance features
Flexibility features
Designed for >60% efficiency in combined cycle
and best in class operational flexibility
Bangkok, Oct. 3 – 5
PowerGen Asia 2012
© Siemens AG 2012
Siemens Energy Sector
Figure 5 Main design features of the SGT-8000H series
11
A key design feature towards operational flexibility and a major concept decision which
had to be made early in the SGT-8000H program, was the selection of the engine cooling
method. Siemens Energy gas turbine portfolio has both types of the major cooling
technologies: The SGT5-4000F and the SGT6-5000F are both based on purely air-cooled
engine concepts, while the SGT6-6000G had a combined air and steam cooled approach.
This experience offered a wide information and experience basis, showing the benefits
and disadvantages of both technologies. Due to the heavy impact of the steam cooling
on the engine operational flexibility and design complexity, the internally fully air-cooled
design was selected for the SGT-8000H. This design feature enables faster starts, since
there is no need to wait for steam from the water/steam cycle. The avoidance of steam
cooling and external coolers enable easier simple cycle and bypass operation, faster load
following and part load operation. Design simplicity especially in terms of sealing designs
provides higher engine robustness. SGT-8000H proven design allows achieving
outstanding performance and operational flexibility without the higher risk associated to
the steam cooling.
A further key aspect which was incorporated in the SGT-8000H was the special focus on
design features to enable easy and quick serviceability:
–
Replacement of compressor blades without rotor de-stack or lift
–
Roll out/in capability of the turbine vane carrier enables exchange of stationary
turbine hardware without rotor lift
–
All turbine blades removable without rotor lift
–
Turbine vane 1 and blade 1 removable without cover lift (access through
combustion chamber)
–
Turbine blade 4 removable without cover lift (towards the exhaust end)
12
2.2.
SCC-8000H combined cycle power plant solutions
As shown in Figure 4 Siemens Energy offers different combined cycle power plant
configurations based on single- and multi-shaft arrangements. Additionally Siemens is
unique in offering a flexible scope of supply varying between entire power plant (turnkey
scope) over power block / power island and up to an extended power train. This enables
Siemens to add – depending on the project specific setup– the regional partners and local
knowledge (Figure 6). The portfolio flexibility with regards to different arrangements and
scope of supply allows a wide range of technical and commercial (risk and cost)
optimizations, allowing best fit to customer’ requirements.
Different scope variations for Siemens combined cycle power plants
Extended
Power Train
Bangkok, Oct. 3 – 5
Power Island
Power Block
PowerGen Asia 2012
Entire Power Plant
© Siemens AG 2012
Siemens Energy Sector
Figure 6 Siemens offers various scopes to customers adding regional partners & local knowledge
A major solution within the product portfolio is the proven single-shaft design that was
developed in the early 90s. Since then, it has since been successfully implemented in the
F-class (SCC5-4000F 1S) with about 100 units in commercial operation. The power plant
SCC-8000H series was developed based on the SGT-8000H as prime mover, the Irsching
4 test plant and the large F class experience as mentioned above. The design principle
comprising the gas turbine, the generator, the coupling and the steam turbine on a singleshaft has remained the same, as this continues to offer the customer the greatest
economy and at the same time supreme operational and financial flexibility. The SCC8000H series is also characterized by its high degree of harmonization, modularization
and compact design towards footprint and space requirements. Both solutions for 50Hz
and 60Hz markets are based on the same design principles.
13
The overall plant design was optimized to provide over 570 MW net power output at
ISO conditions and a net efficiency greater than 60%, while keeping the emissions
extremely low, in this case 25 ppm NOx emissions or less at gas turbine base load (Figure
7). Further performance figures for single and multi-shaft configurations for both 50Hz
and 60Hz are shown in Figure 4.
SCC5-8000H 1S designed for η > 60% and highest
operational flexibility
Published Design
Targets:
Performance (net, ISO)
Power:
>570 MW
Efficiency: > 60%
Steam Turb.:SST5-5000
Combined HP/IP
Dual flow LP
HP: 170 bar / 600 °C
IP: 35 bar / 600 °C
LP: 5 bar / 300 °C
HRSG: BensonTM
3Pr/RH 600 °C/170 bar
Emissions (Base load)
NOx < 25 ppm
CO < 10 ppm
Generator: SGen5-3000W
Water cooled stator winding
Hydrogen cooled rotor winding
MICALASTIC® Stator insulation
World class efficiency
Bangkok, Oct. 3 – 5
Gas Turbine: SGT5-8000H
PowerGen Asia 2012
© Siemens AG 2012
Siemens Energy Sector
Figure 7 SCC5-8000H 1S designed for highest efficiency and operational flexibility
Siemens Energy solutions single shaft design is also optimized for CHP applications.
Despite the compact design with the floor mounted turbine generator train, it’s possible
to provide up to a three stage steam extraction for heating purposes or process steam.
Figure 8 shows the possible heat extraction of both SCC-8000H product lines. In chapter
4 of this paper a commercial reference of the SCC5-8000H 1S with CHP will be
discussed.
14
SCC-8000H
Possible heat extraction in large CHP combined cycles
SCC5-8000H 1S
570MW
SCC6-8000H 1S
410MW
0
50
100
150
200
250
300
350
400
Possible heat extraction [MWth]
SGT5-8000H
Bangkok, Oct. 3 – 5
PowerGen Asia 2012
SGT6-8000H
© Siemens AG 2012
Siemens Energy Sector
Figure 8 SCC-8000H with combined heat & power (CHP) application
The selected steam turbine type used for SCC-8000H series comprises one combined
HP/IP casing and one double-flow low-pressure casing. The advanced steam turbine
design is optimized for combined cycle applications, providing enhanced transient
thermal behavior for fast loading and fast cycling. For the single shaft configuration the
synchronous self shifting (SSS) clutch allows a self-contained individual turning mode of
the gas turbine and the steam turbine increases the operation flexibility and allows also a
faster start-up of the power plant.
Depending on the frequency and plant configuration different generators within the H2
and H2O cooled product lines are used. Both types are contributing to the overall plant
efficiency increase based on its outstanding performance. Due to the large plant output
the 50Hz single-shaft solution is using – as a unique configuration – a generator with
direct radial hydrogen cooling for the rotor winding and water cooling for the stator
winding. This frame is mainly characterized by its high efficiency and reliability beyond
99%. A start-up frequency converter is used for start-up of the turbine generator unit.
15
The generator acts as a motor in the converter mode to start the gas turbine set without
an additional rotating device.
As the SGT5-8000H provides a high exhaust temperature of approximately 625 °C, a
further efficiency increase was achieved based on an advanced three pressure reheat
water steam cycle (up to 600°C inlet temperature and 170 bars inlet pressure) with a
BENSON type heat recovery steam generator (HRSG) and condensate polishing.
Further efficiency improvement measures were based on the use of fuel preheating at
215°C, reduction of pressure losses in the HRSG and piping, feed water pumps with
variable speed drives, etc. The combination of all efficiency improvement measures
enables the major step over 60% efficiency at base load and an efficiency increase of up
to 1,7%-Pt. compared to typical F class over the main operation range.
The Benson-type HRSG for high steam parameters is an essential component in addition
to the "rotating equipment". The HRSG is designed and built by Siemens (Figure 9). As
this component is of major importance for boosting efficiency and flexibility, the
decision was taken to develop and build it in-house on the basis of the available
experience with previous Benson boilers, such as in the projects Karstoe, Simmering and
Timelkam. Due to the increased thermal cycle parameters, advanced high temperature
materials known from the 600 °C steam power plant technology were used for the
HRSG design. For both design standards DIN and ASME Siemens Energy provides
solutions with proven materials for up to 600°C water / steam cycles. Depending on the
plant configuration economics main steam parameters for 50Hz and 60Hz may be
decreased to 150bar and 585°C to enable e.g. the use of a drum type HRSG.
16
HRSG with Siemens BensonTM HP section
designed for 600 °C steam temperature
Irsching 4 BensonTM* HRSG is designed and delivered by Siemens
Proven
Benson
Design
Concept
Siemens Benson HRSG
design, 19 units built, e.g.
Malzenice, Gönyü, Severn
Power, Sloe Centrale…
Siemens
Design
Principles
Based on F-class
technology as executed
in e.g. Karstoe,
Simmering, Timelkam
HRSG + Plant
Development
in one Hand
=
ƒ HP pressure/Temp.: 170 bar/600 °C
Benson
Evaporator
Design
Based on Siemens
BensonTM Technology*
(Elimination of HP drum)
600 °C
Technology
Utilization of high
temperature materials
applied for 600 °C
Steam Power Plants
ƒ RH pressure/Temp: 35 bar/600 °C
ƒ Mass flow:
100 kg/s
ƒ Weight:
~ 7000 tons
ƒ Heating surface:
> 500.000 m²
(*) Siemens is owner of the BensonTM patent
Bangkok, Oct. 3 – 5
PowerGen Asia 2012
Innovation based
on proven
technology and
materials
© Siemens AG 2012
Siemens Energy Sector
Figure 9 BENSON HRSG designed for 600 °C steam temperature
All flexibility features – well known from our SCC5-4000F series – were implemented in
SCC5-8000H. The FACY (FAst CYcling) concept with its key components is
summarized in Figure 10.
17
SCC5-8000H 1S – a proven concept optimized for
highest operational flexibility
High-capacity
de-superheater
Stack damper
BensonTM
technology
ST stress
controller
FACY
Fast Cycling
Advanced
steam parameter
Up to 600 °C
Optimized GT
load ramp
HRSG standby heating
Low complexity
(No GT external
cooling interface)
Condensate
polishing plant
Proven cycle
concept
Triple pressure
reheat cycle
Specific features included in our advanced 8000H plant cycle design for
most flexible and reliable operation
Bangkok, Oct. 3 – 5
PowerGen Asia 2012
© Siemens AG 2012
Siemens Energy Sector
Figure 10 SCC5-8000H 1S optimized design to allow highest operational flexibility
The implementation of the FACY concept in combination with the hot start on-the-fly
allows a hot start-up time reduction down to less than 30 minutes in comparison to
“conventional” hot starts. The concept is based on a procedure for parallel start-up of
gas and steam turbines, while monitoring and controlling the temperature gradients
within limits acceptable for all critical plant components and long term operation
experience with different steam conditions in the Siemens turbine design. A new start-up
sequence, which avoids gas turbine load hold points, was implemented. The main
innovation here is the early steam turbine starting point with earlier acceleration and
loading of the turbine. The FACY technology allows for higher number of starts and
faster cycling without compromising plant lifetime consumption.
18
3. Operational experience
3.1.
Test and validation of the SGT5-8000H and SCC5-8000H
The 8000H program was started in 2000, and after thorough development and
engineering successful component testing paved the way to the first field installation in a
simple cycle configuration built by Siemens for E.ON Kraftwerke in the Irsching site
(Figure 11).
Irsching Units 1 - 5, as of June 2011
Owned by E.ON Kraftwerke
Block #4 – SCC5-8000H 1S
Ulrich Hartmann
Block #5 – SCC5-4000F 2x1
Bangkok, Oct. 3 – 5
PowerGen Asia 2012
© Siemens AG 2012
Siemens Energy Sector
Figure 11 Irsching power plants – Unit 4 built based on SCC5-8000H 1S and the first commercial
SGT5-8000H
First firing took place in December 2007. First synchronization to the grid occurred on
March 7, gas turbine base load was achieved on April 24, 2008, and the field validation
program was successfully completed in August 2009, after over one and a half years in
simple cycle operation. The total 18-month validation program consisted of multiple
measurement campaigns, covering the full operating range starting from hot
19
commissioning to a final endurance test in open cycle configuration. This validation
phase confirmed its functionality, operational capability, performance, serviceability,
integrity and stability limits.
Following completion of GT field validation in August 2009, extension and conversion
to a combined cycle power plant started at Irsching and was completed on schedule in
December 2010. The conversion to a complete combined cycle power plant went off
without hitch within a very tight time frame of only 16 months. With the re-ignition of
the gas turbine in its new configuration for the first time in January 2011 and steam
admission just few weeks later, the commissioning phase, including the final test and
validation of the entire combined cycle power plant, was begun. Only few days after this,
in March 2011, it was possible to run the plant at combined cycle base load for the first
time. The further commissioning activities up to June 2011 were marked by tests to
validate the performance of the components and the overall thermal cycle and to
demonstrate the plant's high operational flexibility and capability in meeting the most
stringent grid requirements, to optimize the startup times and load rejections, and to
verify its output and efficiency.
Once all tests were completed, the plant was adjusted to the guarantee conditions, which
were agreed with E.ON in 2005 and increased in 2008 (in terms of output, efficiency,
emissions and startup times). During the customer performance test the plant achieved
for the first time in the history of power plant engineering a net electrical efficiency of
60.4% while producing at the same time a unit net output of 561 MW complying with all
contractually defined emission limits. The achieved efficiency level and the low emissions
(NOx below 25 ppm and CO below 10 ppm) make Irsching 4 – SCC5-8000H 1S a
milestone in environmentally friendly fossil power generation
In terms of operational flexibility following results were achieved under combined cycle
operation conditions:
–
Fast hot start-up using FACYTM technology and hot start on the fly: the overall
plant can be very reliably run up to full load in less than 30 minutes, putting over
500 MW in to the grid at combined cycle load ramps up to 50MW/min. It should
20
be mentioned that under simple cycle operation conditions, GT full load can be
achieved within 10 minutes at GT load ramps of 35MW/min.
–
Plant fast shut down was achieved in less than 30 minutes. During the combined
cycle operation fast plant de-loading was also tested to demonstrate its ability to
run under stable conditions at minimum load (combined cycle load of approx.
100MW or less than 20% of rated output with both GT and steam turbine in
operation).
–
Fast cycling dynamic load tests showed excellent capability to effectively
contribute to grid stabilization and to run in a fast load following mode. Load
gradients up to 35 MW/min. were demonstrated and the plant achieved over 200
MW load increase and decrease in less than 7 minutes, while all systems were
running under perfectly stable conditions.
–
Grid support capability: The UK grid code is the most stringent in the world.
Two major aspects of the UK grid code define the requirements for frequency
response and load stabilization in case of island grid formation. In terms of
primary and secondary frequency response, the Irsching 4 plant surpassed the
UK grid code target as a 12% load increase initiated by a simulated frequency
drop was demonstrated in less than 10 seconds. In order to fulfill the island
formation requirement a load reduction of 45% within 6 seconds as an
instantaneous answer to the detected frequency deviation in the gas turbine
controller was achieved. Such capabilities are indispensable to allow effective grid
stabilization and avoidance of grid blackouts, especially within small grids.
Prior to customer handover world record performance test runs were done. The plant
was operated and tested according to its design conditions. These runs have
demonstrated, also under the supervision and verification of the independent certified
body TÜV, the potential that this plant harbors in this configuration for further planned
commercial projects. The achieved performance at Irsching 4 reference site conditions
were:
–
Power output of 578 MW
21
–
Efficiency of 60.75% (net) with compliance to the emission limits.
Since the customer handover in July 2011, the gas turbine SGT5-8000H has achieved in
the Irsching 4 power plant in sum more than 17,000 equivalent operating hours (whereof
more than 12,5000 EOH in combined cycle operation) and more than 400 starts (Figure
12).
Operational Record Ulrich Hartmann CCPP
Irsching unit #4 as of July 30, 2012
Phase I
GT Testing (open cycle)
Phase II /
Combined cycle plant operation
Starts
85
326
Total EOH
4.365
12.689
Grand Total
GT > 17.054 EOH
Combined Cycle > 12.689 EOH
Irsching 4 is running with outstanding availability and startup reliability
Bangkok, Oct. 3 – 5
PowerGen Asia 2012
© Siemens AG 2012
Siemens Energy Sector
Figure 12 Operating experience gained in Irsching 4
Since commercial operation two planned short time outages after 6,000 EOHs and 8,000
EOHs were performed and allowed a visual inspection of the hot gas path and
confirmed the anticipated excellent engine conditions. Based on these results the decision
was made to potentially defer the combustor inspection to the 12,000 EOHs outage.
After a further visual inspection at 10,000 EOH finally the combustor inspection took
place during the outage in May 2012. The engine conditions and the hot gas path
components were found to be in excellent conditions. Since then the unit was brought
back in service successfully.
22
With start of the commercial operation the combined cycle unit 4 in Irsching
impressively showed its ability as a daily start/stop unit. Figure 13 shows the typical
dispatch situation of Irsching unit 4. Although the plant was designed and sold as a base
load unit, the current dispatch situation can be perfectly matched thanks to the plant’s
capacity in terms of operational flexibility. The plant is typically starting up early in the
morning with the increasing power demand. Over the day the unit is running in a load
following mode with a cycling load profile between full load and 50 – 60% part load at
the time same meeting the emission compliance and expected efficiency. Overnight shut
downs enable our customer to save fuel cost and unnecessary emissions of NOx, CO
and CO2. The intensive monitoring of Irsching 4 shows outstanding plant availability and
starting reliability, which is necessary for a daily cycling operating regime.
Operation profile of Irsching 4
Jun. 11 – Jun. 25, 2012
GT speed
Plant output
Monday
Monday
Bangkok, Oct. 3 – 5
PowerGen Asia 2012
© Siemens AG 2012
Siemens Energy Sector
Figure 13 Typical daily load profiles of Irsching unit #4
3.2.
Test and validation of the SGT6-8000H
The SGT6-8000H is a full scaled design (geometry factor 1.2) to the SGT5-8000H. The
major difference is the number of burners (12 instead of 16) and the related design
23
adjustments (e.g. casing; transition from burner to turbine vane 1) in order to be able to
use the same combustion system for 50 and 60Hz Version.
Siemens has a vast and long lasting experience in scaling gas turbine design (e.g. SGT52000E/SGT6-2000E or SGT5-4000F/SGT6-4000F). This approach allowed Siemens to
achieve a relative short design phase for the 6-8000H; in fact the design of the SGT68000H was initiated during the validation phase of the SGT5-8000H while the first
commercial contract was signed only 2 years later. Of course the approach to start design
after having already 50Hz validation results available significantly increased the
confidence in achieving the desired design targets. There is still some remaining risk in
scaling, especially for the non-scaled design parts. Examples are turbine inlet temperature
profile; the specific transition-piece from combustor to turbine inlet and even production
processes for the individual parts.
Siemens experience in scaling allows for precise prediction of the items in question.
However, in order to further limit the implementation risk of such a scaled prototype for
both customer and Siemens, it was decided to perform a stringent test- and validation
program also for the SGT6-8000H. Even if the risk for such an event is low, any
unexpected prototype issue will cost both OEM and customer valuable time and money,
if experienced during commissioning in a commercial project. Siemens policy is to avoid
this. Therefore the 60Hz 8000H engine was implemented in the Berlin Test Facility
within the Berlin gas turbine factory. Connected to a water brake instead of a grid
connection via a generator, the engine can be operated at the design frequency of 60Hz
as well as any desired under- and over-frequency despite being located in a 50Hz region.
After a significant rebuilt of the test center in 2010/2011 the first SGT6-8000H was
operated for a ca. 10 months test phase.
24
Test Bed in Berlin allowing up to 300 MW Testing at various
speed conditions thanks to a water brake concept
Bangkok, Oct. 3 – 5
PowerGen Asia 2012
© Siemens AG 2012
Siemens Energy Sector
Figure 14 Berlin gas turbine test bed facility
Focus of the validation phase was threefold. One target was to confirm the design of the
scaled engine like hardware integrity, thermodynamical behavior, emission profile etc.
Second target was to confirm the validation results of the SGT5-8000H. Third target was
to add some additional test topics that were not conducted in Irsching like oil operation
or sub-25ppm NOx operation. The test program was structured accordingly. The first
test phase consisted of a baseline testing while oil operation or sub-25ppm NOx testing
was conducted after corresponding outages.
The targets of the SGT6-8000H test program were fully achieved. The data retrieved
confirmed both performance prediction of SGT6-8000H and SGT5-8000H; all engine
parameters (temperatures, pressures etc.) were as expected; predicted temperature
profiles were confirmed via thermal paint testing; under- and over-frequency behavior of
the engine was confirmed; operational behavior on both fuel gas and fuel oil did meet the
requirements. Lessons learned from the validation phase are implemented in the
production engines for the commercial projects; as a result any impact on the commercial
projects could be avoided. So it can be concluded that the approach to validate also
25
the scaled SGT6-8000H did prove to be beneficial for both Siemens and the Siemens
customers.
26
4. Market launch and first commercial references
With the successful conclusion of Irsching 4 and the related validation and testing
phases, Siemens Energy is the first OEM to operate a gas turbine engine and a combined
cycle plant with efficiency far beyond 60%. Siemens impressively demonstrated that
world-record technology is commercially available to the customers and that the 8000H
technology has a clear advance of years on the gas turbine and combined cycle market.
Despite the direct scale approach, the full scale 60Hz engine was tested in the Berlin test
facility, prior to shipment to first customer’s site. Indeed the next commercial success
was achieved in Florida, USA, where 6 units of the SGT6-8000H were placed. Both
Florida Power & Light sites in Riviera Beach and Cape Canaveral are equipped with the
8000H gas turbine in a multi-shaft configuration (3 on 1) and provide approximately
1200 MW electrical energy each. At the same time period the next order from South
Korea for the supply of a complete combined cycle power plant equipped with the
SGT6-8000H in a single shaft configuration was placed by the independent power
producer GS Electric Power & Services, Ltd. As a consortium leader, Siemens is
installing the 400MW class power plant Bugok 3 as a turnkey project. In 2012 further six
units were successfully sold in South Korea, with ANSAN as a multi-shaft configuration
and ANDONG, POSCO as a single shaft arrangement. The first 60Hz units will start the
commercial operation already in summer 2013. Following the success in Asia Siemens
Energy has received an order for turnkey erection of the Lausward combined cycle
power plant with district heat extraction in Düsseldorf, Germany. The order was placed
by Stadtwerke Düsseldorf AG (SWD). With an electrical unit output of around 595MW
and a net efficiency of over 61% as a single shaft arrangement, the Lausward CCPP will
set a new world record. In addition, the generated thermal energy will be used for the
district heating system in the city of Düsseldorf. Never before has it been possible to
extract 300 MWth of district heat from a single power plant unit in combined cycle
operation. Thus, the overall efficiency of the natural gas fuel will be around 85 percent.
The Lausward CCPP plant will be one of the most efficient and environmentally
sustainable plants in the world. An overview of the references of the SGT-8000H and
accordingly SCC-8000H is shown in Figure 15 SGT-8000H & SCC-8000H references
27
SGT-8000H References
Ulrich Hartmann – Irsching 4, Germany
1x SCC5-8000H 1S, >17.000 EOH
Cape Canaveral / Riviera Beach, Florida, USA
2x SCC6-8000H 3x1, COD 05/2013, COD 05/2014
Bugok 3, South Korea
1x SCC6-8000H 1S, COD 08/2013
Ansan, South Korea
1x SCC6-8000H 2x1, COD 01/2015
Andong, South Korea
1x SCC6-8000H 1S, COD 04/2014
Lausward, Germany
1x SCC5-8000H 1S CHP, COD 02/2016
Düsseldorf,
Düsseldorf,
´Center
´Center
Posco Power 2, South Korea
3x SCC6-8000H 1S, COD 11/2014, 02/2015, 05/2015
Status: August 2012
15 SGT-8000H gas turbines sold
Bangkok, Oct. 3 – 5
PowerGen Asia 2012
© Siemens AG 2012
Siemens Energy Sector
Figure 15 SGT-8000H & SCC-8000H references
28
5. Conclusion
This paper provides an overview regarding the Siemens SGT-8000H and the related
SCC-8000H series product portfolio. The core engine of Siemens’ H Class is fully air
cooled without having any external interfaces to external coolers. This key design feature
is decisive for shifting the operational flexibility of the overall solution beyond the
existing F Class limits, while providing a net performance far above 60%.
The main elements of the different solutions for 50Hz and 60Hz were presented.
Siemens’ H Class product portfolio is based on single shaft and multi shaft arrangements
with optimized water / steam cycle and live steam parameters up to 600°C and 170 bars.
The product portfolio offers several solutions with a flexible scope of supply, which
drastically reduce life cycle costs and specific investment costs.
The SGT-8000H is fully field tested and validated. An overview about all activities prior
to market introduction was shown and which demonstrates Siemens’ approach in
keeping the overall technology risk and hence customer’s risk at a low level. The Irsching
unit #4 has already achieved more than 17,000 EOHs in commercial operation and has
impressively demonstrated the high level of gas turbine and plant availability and starting
reliability. In addition, the full scale 60Hz engine is tested and validated in the Berlin
plant test facility prior to customer’s site shipment in order to limit remaining scaling
risks. The operational records of our field validations and commercial operation have
confirmed our expectations towards engine design reliability.
Siemens 8000H product lines are the result of a long term development program with
significant financial investments, demonstrating Siemens commitment to meet
customer’s expectations and to durably improve customer’s value. Since commercial
29
availability 151 units were sold. This great success confirms the achievements in design,
test and validation over more than a decade.
1
Status August 2012
30
6. References
[1]
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Walke, P. Rimmington, D. Wasdell, “Design and Validation of a Compressor for a
New generation of Heavy-Duty Gas Turbines”, ASME Power Conference 2007,
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[2]
P. Ratliff, P. Garbett, W. Fischer, “SGT5-8000H Größerer Kundennutzen durch die
neue Gasturbine von Siemens”, VGB PowerTech, September 2007
[3]
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[4]
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[5]
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Garbett, P. Ratliff, “Planning for Extensive Validation of the Siemens H-Class Gas
Turbine SGT5-8000H at the Power Plant Irsching”, ASME Power Conference, July
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[7]
W. Fischer, S. Abens, “SGT5-8000H Design and Product Validation at Irsching 4
Test Center”, VGP Power Tec 09/2009
[8]
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System for the SGT5-8000H and First Experiences in the Irsching Power Plant”,
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[9]
W. Fischer, “SGT5-8000H / IRSCHING 4: On The Way To 60% World Record
31
Efficiency And Path To 60 Hz SGT6-8000H”, 18th Conference of the Electric Power
Supply Industry (CEPSI), Taipei, Taiwan, Oct. 2010
[10] Dr. S. Abens, W. Fischer, „SGT5-8000H / IRSCHING 4, On the way to 60 %
World Record Efficiency And Path to 60 Hz SGT6-8000H”, PowerGen Asia,
Singapore, Nov. 2010
[11] L. Balling, Dr. U. Tomschi, A. Pickard, G. Meinecke, “Fast Cycling and Grid Support
Capability of Combined Cycle Power Plants to optimize the Integration of
Renewable Generation into the European Grid: Live examples from projects in NL,
F, UK, D”, PowerGen Europe, Amsterdam, June. 2010
[12] Dr. K. Sfar, T. Hagedorn, “Siemens H Class CCPP Technology: Implementation of
the first 50Hz unit and update on latest 60Hz plant design standard”, PowerGen
Asia, Kuala Lumpur, Sept. 2011
[13] W. Fischer, A. Städtler, “SGT5/6-8000H & SCC5/6-8000H Product Line: Advanced
Generation of High Performance Gas Turbine and Combined Cycle System”, 6th
IDGTE GT Conference, Milton Keynes, November 2011
[14] A. Städtler, “SGT5-8000H/SCC5-8000H 1S First experience of Commercial
Operation at Irsching 4”, Russia Power, Moscow, March 2012
[15] W. Fischer, “SGT-8000H Product Line: Actual Update”, PowerGen Euorpe,
Cologne, Jun. 2012
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7. Copyright
The content of this paper is copyrighted by Siemens AG Energy Sector and is licensed
only to PennWell for publication and distribution. Any inquiries regarding permission to
use the content of this paper, in whole or in part, for any purpose must be addressed to
Siemens AG Energy Sector directly.
8. 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
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others, from changes in general economic and business conditions, changes in currency
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SEC’s website, www.sec.gov. Should one or more of these risks or uncertainties
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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, its affiliates or their respective owners.
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